US20110150579A1 - Continuous chamber mass confinement cells and methods of use thereof - Google Patents
Continuous chamber mass confinement cells and methods of use thereof Download PDFInfo
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- US20110150579A1 US20110150579A1 US12/987,835 US98783511A US2011150579A1 US 20110150579 A1 US20110150579 A1 US 20110150579A1 US 98783511 A US98783511 A US 98783511A US 2011150579 A1 US2011150579 A1 US 2011150579A1
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D29/00—Independent underground or underwater structures; Retaining walls
- E02D29/02—Retaining or protecting walls
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D29/00—Independent underground or underwater structures; Retaining walls
- E02D29/02—Retaining or protecting walls
- E02D29/0225—Retaining or protecting walls comprising retention means in the backfill
- E02D29/0241—Retaining or protecting walls comprising retention means in the backfill the retention means being reinforced earth elements
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D29/00—Independent underground or underwater structures; Retaining walls
- E02D29/02—Retaining or protecting walls
- E02D29/025—Retaining or protecting walls made up of similar modular elements stacked without mortar
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- E—FIXED CONSTRUCTIONS
- E02—HYDRAULIC ENGINEERING; FOUNDATIONS; SOIL SHIFTING
- E02D—FOUNDATIONS; EXCAVATIONS; EMBANKMENTS; UNDERGROUND OR UNDERWATER STRUCTURES
- E02D29/00—Independent underground or underwater structures; Retaining walls
- E02D29/02—Retaining or protecting walls
- E02D29/0258—Retaining or protecting walls characterised by constructional features
- E02D29/0266—Retaining or protecting walls characterised by constructional features made up of preformed elements
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Abstract
The present invention relates to mass confinement cells that may be used in retaining walls and earth retention systems that has a natural earthen appearance or other aesthetic design and is resistant to damage and wear caused by the environment. The mass confinement cells are generally light-weight and include a continuous chamber that at least partially aligns with confinement cells positioned above and below, thereby allowing the intermingling of fill material between adjacent cells. The mass confinement cells are capable of accepting and retaining any type of filling material. The filling material provides weight, stability and security to a retaining wall constructed of such mass confinement cells.
Description
- This application is a continuation of U.S. application Ser. No. 11/463,816 filed on Aug. 10, 2006, which claims priority to U.S. Provisional Application Ser. No. 60/707,032, filed on Aug. 10, 2005, U.S. Provisional Application No. 60/741,737 filed on Dec. 2, 2005, and U.S. Provisional Application No. 60/777,617 filed on Feb. 28, 2006. The contents of the four previously mentioned applications are incorporated by reference herein.
- The present invention relates to environment resistant landscaping products, such as mass confinement cells for retaining wall and earth retention applications, that in various embodiments provide a natural earthen appearance, such as rock, stone, sand, soil, clay, wood, trees and foliage, water, or any other natural earthen appearance. The mass confinement cells may also include a fascia having a natural earthen appearance or other aesthetically appealing design that is resistant to damage and wear caused by the environment. The mass confinement cells are generally light-weight and include a frame adjoined to one or more chamber enclosing members, thereby forming a continuous chamber. The continuous chamber of each cell are designed to at least partially align with confinement cells positioned above and below, thereby allowing the intermingling of fill material between adjacent cells. The mass confinement cells are capable of accepting and retaining any type of filling material that generally provides weight, stability and security to a retaining wall constructed of such mass confinement cells.
- The use of retaining walls to protect and beatify property in all types of environmental settings is a common practice in the landscaping, construction and environmental protection fields. Walls constructed from various materials are used to outline sections of property for particular uses, such as gardens or flower beds, fencing in property lines, reduction of erosion, stabilizing construction sites in potentially unstable or rough terrain and to simply beautify areas of a property.
- Numerous methods and materials exist for the construction of retaining walls. Such methods include the use of natural stone, poured in place concrete, masonry, landscape timbers or railroad ties. In recent years, segmental concrete retaining wall units, sometimes known as dry-cast block, which are dry stacked (i.e., built without the use of mortar), have become a widely accepted product for the construction of retaining walls. Examples of such units are described in U.S. Pat. No. RE 34,314 (Forsberg) and in U.S. Pat. No. 5,294,216 (Sievert).
- However, many of the materials utilized in the construction of retaining walls are susceptible to deterioration, heavy, cumbersome and/or not very aesthetically appealing. The ability of these retaining walls to withstand sunlight, wind, water, general erosion and other environmental elements is a problem with most retaining wall products.
- One particular concern is the utilization of erosion protection materials in water shorelines. Leaving the shoreline natural can lead to erosion, cause an unmanageable and unusable shoreline, create high maintenance, and potentially destroy an aesthetically pleasing property. Many materials utilized in retention of shorelines are subject to immediate deterioration and/or are not as aesthetically appealing as one would desire. Furthermore, many materials utilized on shoreline structures are difficult to maintain due to the awkward location in the water and also the prevalent growth and presence of organic materials that can get caught and flourish in such a structure. For example, many lakeshore or ocean side properties utilize riprap as a retention device for prevention of erosion. Riprap is a configuration of very heavy, large to medium size stones placed along the shoreline. One problem with waterfront properties that use a continuous wall of typical riprap is the shoreline will retain some organic material, will accumulate additional organic material brought in by the water and/or will allow vegetation to grow within the openings between stones. This usually leads to an unmanageable and aesthetically displeasing shoreline or higher maintenance. Furthermore, the riprap is never uniform in color and size and therefore does not provide the most aesthetically pleasing shoreline or complete coverage of the shoreline. The lack of uniform shoreline coverage allows for some erosion, collection of unwanted materials and the potential growth of undesirable vegetation.
- Another problem with materials normally utilized in the construction of retaining walls, such as poured in place concrete, masonry, landscape timbers, railroad ties or dry-cast blocks (e.g. blocks produced by Keystone® Inc. or Anchor® Retaining Wall Systems, Inc.) is that regulations in most states and counties prohibit their use in or near bodies of water because of the potential chemical diffusion into the body of water and/or the crumbling or deterioration of the material into the body of water over time. Many of these retaining wall materials diffuse chemicals, dissolve, crumble, break apart and/or float into the body of water of which they are lining, thereby causing problems with the shoreline and pollution of the water. For example, the average life of various types of dry-cast block in water environments is approximately a couple of years. A need exists for a retaining wall, which would be resistant to such deterioration.
- An additional concern that exists in the construction of retaining walls is the weight of the materials. Concrete blocks (e.g. wet or dry cast), large or medium size stones or timbers can be heavy and cumbersome to move into the wall location and maneuver when constructing retaining walls and earth retention systems. Many locations for which retaining walls are constructed are positioned in awkward terrain. Therefore, heavy building materials are difficult to move into such locations and furthermore are difficult to position when constructing the retaining wall, thereby adding additional cost and labor for installation. However, the heavy materials can be beneficial once the wall is constructed to provide stability and security to the structure. Therefore, what is needed are easy to install light-weight units used for the construction of retaining walls and earth retention systems, which can be weighted once placed into position thus retaining the units in position and stabilizing the completed retaining wall.
- Embodiments of the present invention relate to retaining wall products including mass confinement cells that are resistant to damage and wear caused by the environment. The mass confinement cells generally include a frame adjoined to one or more enclosing members to form a continuous chamber, which allows the flow of fill material to adjacent confinement cells below and above. The deterioration resistant mass confinement cell is generally a hollowed frame or shell that includes a deterioration resistant material that is light-weight and is configured to interlock with adjacent confinement cells, thereby forming a continuous chamber system capable of accepting and retaining any type of filling material. The filling material provides weight, density, structure and stability to the mass confinement cells and also ultimately provides stability and security to the retaining wall constructed of such cells.
- Various embodiments of the deterioration resistant mass confinement cells of the present invention comprise a frame adjoined with one or more chamber enclosing members to form a mass confinement cell having a continuous flow chamber. The frame in various embodiments of the present invention may include two or more panels that are hingedly adjoined to allow the panels to position in a flattened configuration, thereby providing transportation and storage efficiencies. In various embodiments at least two of the panels extend from the front of the cell to the back of the cell at angles (e.g. less than 90°), thereby allowing for the back of the cell to be shorter in length than the front of the cell. This configuration allows for curving of walls or revetments when constructing a wall. The continuous flow chamber of these mass confinement cells generally forms a series of integrated channels when placed in a wall or earth retention structure, thereby allowing the flow of fill material between adjacent confinement cells.
- The cells of the present invention may further include one or more anchoring devices for securing each cell to adjacent cells or securing them into position in the retaining wall. In various embodiments of the present invention one or more of the panels include one or more locking pegs or peg extensions for interconnecting the stacked confinement cells. The locking pegs or peg extensions assist in positioning and/or adjoining adjacent cells and facilitating the flow of fill material to the adjacent cells. Additionally, the locking pegs or peg extensions assist in retaining the fill material within the adjoined confinement cells and also may lock the adjacent cells to each other. As previously suggested, the continuous chambers are adapted for receiving and retaining fill materials, such as sand, dirt, gravel, pea rock, class V, concrete or any other similar material, which provides the permanent weighting and stability of each retaining wall cell.
- In additional embodiments of the present invention, the cells may comprise a frame including two or more separated panels that are fixedly adjoined by a securing mechanism, such as a “peg and socket system”. For example, a front panel, side panels and/or back panel may be separate panels that are secured together to form the confinement cells of the present invention. These embodiments provide the benefits of providing two or more substantially flat panels and/or nestable panels that may be assembled to form each cell. Also, such a process may open other beneficial manufacturing techniques to form such panels, such as extrusion, thermoforming and vacuum forming. Such embodiments will also generally provide benefits related to transportation and storage.
- In yet other embodiments of the present invention, the mass confinement cells include a frame operably adjoined to a load cell and fascia. The load cell of these embodiments generally includes a cylinder that is intended to bear the majority of the load of the fill material, thereby protecting the fascia and front panel of the frame or front chamber enclosing member. Similar to the previous embodiments there are transportation and storage benefits in these embodiments in that the various components nest or may be transported in a flat configuration.
- Embodiments of the deterioration resistant mass confinement cells of the present invention may be used in constructing retaining walls and earth retention systems on a number of property terrains, such as along waterfront properties or along gradual or steep embankments. The deterioration resistant confinement cells are particularly useful for terrains near water or underwater due to their resistance to degradation. However, the deterioration resistant cells could also be used for land applications for those that want a light-weight retaining wall product that can be filled on-site to add weight and stability and also does not require heavy equipment for moving and installing. Therefore, the deterioration resistant mass confinement cells could be utilized to construct any form of wall, earth retention system or fence structure.
- One unique feature of the present invention is the lightweight characteristic of each confinement cell before it is filled and the stable and weighted characteristic after it is filled. As previously mentioned, embodiments of the present invention may be filled with any type of fill material located at the site, such as rocks (e.g. crushed rock and pea rock), sand, gravel, soil, concrete or similar materials. The filling characteristic of the deterioration resistant confinement cells means that when the cells are not filled they are very light-weight. This light-weight feature provides individuals constructing such walls the advantage of easily moving large numbers of the confinement cells to the site of construction with relative ease. Furthermore, the lightweight characteristic of such cells allows for easy maneuvering of the cells into final position when constructing a retaining wall or revetment, but still allows for the stability as found in heavy concrete products when these same confinement cells are filled. These characteristics are met by each mass confinement cell being made of a lightweight material, such as plastic (e.g. high density polyethylene), and by it also being configured to receive a heavy fill material once it has been placed in its final position on the retaining wall.
- Individuals would be more inclined to install products made of a deterioration resistant material, rather than cement block, timbers, dry cement process (or dry-cast) block (e.g. Keystone® or Anchor® block) and the like, because of their installation ease attributed to the light-weight properties and enhanced longevity. The weight of most regular retaining wall block is approximately 12-120 lbs, whereas embodiments of the present invention are approximately 2-20 lbs. Of course, weight may vary depending on the size and materials utilized in manufacturing embodiments of the present invention.
- Embodiments of the present invention are also superior to other retaining wall products due to the precise nature of the materials and manufacturing processes. Such processes generally exhibit minimal to no difference in unit dimensions and feature characteristics, thereby allowing for precision in product specifications and building structures with such units. Examples of possible manufacturing methods include but are not limited to injection-molding, structural foam molding (e.g. low pressure multi-nozzle structural foam), extrusion, roto-molding, thermoforming, vacuum forming and blow-molding. However, it is noted that any high volume application for production may be utilized in manufacturing the present invention.
- The individual units of the present invention are light-weight, aesthetically pleasing, easy to install, prevent shoreline and other terrain erosion and compliment preexisting retaining wall products. Various embodiments of mass confinement cells of the present invention are also waterproof or absorption resistant, can withstand ice damage due to their flexible nature and are easily replaced or repaired in case of damage. Furthermore, the confinement cells of the present invention are rugged and require very low maintenance. Additionally, embodiments of the present invention are easily transportable, storable and installable due to their light-weight and possible stacking and/or nesting features.
- As previously suggested, embodiments of the present invention are also resistant to deterioration, such as wear, discoloration, crumbling and breaking. Therefore, the deterioration resistant mass confinement cells do not have to be replaced as often and/or increase the lifespan of the retaining wall or earth retention system. Due to these characteristics, the cells of the present invention generally have a much greater lifespan than the life of a regular dry-cast concrete type block or timber. The increased lifespan of the confinement cells translates to fewer or no occurrences of replacement of individual cells or the potential complete reconstruction of the entire wall. Furthermore, retaining wall materials, such as concrete block formed by the dry cast process, (e.g. Keystone® blocks) and timbers are typically not used in water applications because they dissolve, crumble and/or break down over time and exposure. The durability and deterioration resistant characteristics of the present invention reduce and prevent the structural degradation of this product, thereby making it beneficial for all applications that come in contact with water.
- Another advantage of embodiments of the present invention relates to the high cost of waterfront property and people's inclination to improve their property to keep it well-maintained and aesthetically pleasing. As previously mentioned riprap, is commonly stacked along property shorelines to prevent erosion. The trouble with this shoreline preservation application is that rip rap is generally incredibly heavy, thereby making it difficult to install. Furthermore, rip rap will leave many crevices for organic material to reside and, since it is close to water, the crevices are prominent areas for the growth of vegetation.
- In addition, many waterfront properties suffer water damage when water levels rise above the shoreline. The mass confinement cells of the present invention are a solution to water retention and erosion problems in such areas of threatening high or rising water levels. Furthermore, the mass confinement cells pose a solution in locations where there is a flood plane or areas that are washed out by any type of water movement. Sandbags have been a solution to such problems, but are not a permanent or aesthetically pleasing solution. The retaining wall cells can replace sand bags in an area for which a more permanent and aesthetically pleasing alternative is desired.
- As previously suggested, the deterioration resistant mass confinement cells can be produced in any type of shape, configuration, color and design. In addition each confinement cell may include any design or color located anywhere on one or more panels or walls of the confinement cell.
- In summary, the utilization of conventional type materials for retaining walls, such as concrete blocks (wet or dry cast), timbers, rip rap and other wall or revetment construction materials, have caused problems related to their inherent weight, deterioration tendencies and aesthetic deficiencies. Therefore, the present invention provides an aesthetically pleasing, durable and easy to use product for all persons intending to construct a retaining wall or earth retention system.
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FIG. 1 is a front perspective view of one embodiment of a deterioration resistant mass confinement cell. -
FIG. 2 is a back perspective view of an embodiment of a deterioration mass confinement cell. -
FIG. 3 a is a front perspective view of an embodiment of a front panel of a deterioration resistant mass confinement cell. -
FIG. 3 b is a back perspective view of an embodiment of a front panel of a deterioration resistant mass confinement cell. -
FIG. 4 a is a front perspective view of an embodiment of a back panel of a deterioration resistant mass confinement cell. -
FIG. 4 b is a front perspective view of an embodiment of a back panel of a deterioration resistant mass confinement cell. -
FIG. 5 is a perspective view of an embodiment of a side panel of a deterioration resistant mass confinement cell. -
FIG. 6 is a perspective view of one embodiment of an adjoined back panel and side panels of a deterioration resistant mass confinement cell positioned in a flat configuration. -
FIG. 7 is a front perspective view of one embodiment of an adjoined back panel and side panels of a deterioration resistant mass confinement cell positioned in a folded assembly configuration. -
FIG. 8 is an exploded view of one embodiment of a deterioration resistant mass confinement cell. -
FIG. 9 a is a perspective view of an embodiment of a deterioration resistant mass confinement cell including a peg and socket securing mechanism. -
FIG. 9 b is a perspective view of the Detail A peg and socket securing mechanism ofFIG. 9 a. -
FIG. 9 c is a perspective view of the Detail B peg and socket securing mechanism ofFIG. 9 a. -
FIG. 10 is a front perspective view of an embodiment of a deterioration mass confinement cell including a peg and socket securing mechanism, stabilizing partitions and anchoring pins. -
FIG. 11 a is a front perspective view of one embodiment of a stabilizing partition. -
FIG. 11 b is a back perspective view of one embodiment of a stabilizing partition. -
FIG. 12 is an exploded front view of one embodiment of a deterioration resistant mass confinement cell including a peg and socket securing mechanism, stabilizing partitions and anchoring pins. -
FIG. 13 is a front perspective view of one embodiment of a deterioration resistant mass confinement cell including a stabilizing partition. -
FIG. 14 is an exploded view of one embodiment of a deterioration resistant mass confinement cell including a frame, enclosing member and fascia. -
FIG. 15 a is a front perspective view of an embodiment of the frame of the deterioration resistant mass confinement cell ofFIG. 14 in a folded assembly position. -
FIG. 15 b is a back perspective view of an embodiment of the frame of the deterioration resistant mass confinement cell ofFIG. 14 in a folded assembly position. -
FIGS. 16A-D are top, front, back perspective and side views of an embodiment of the frame of the deterioration resistant mass confinement cell ofFIG. 14 in a flat configuration. -
FIG. 17A is a front perspective view of an embodiment of an enclosing member of the deterioration resistant mass confinement cell ofFIG. 14 . -
FIG. 17B is a back perspective view of an embodiment of an enclosing member of a deterioration resistant mass confinement cell ofFIG. 14 . -
FIG. 18A is a front view of one embodiment of a fascia that may be utilized with the deterioration resistant cells of the present invention. -
FIG. 18B is a back view of one embodiment of a fascia that may be utilized with the deterioration resistant cells of the present invention. -
FIG. 19 is a front perspective view of one embodiment of a deterioration resistant mass confinement cell of the present invention that includes a frame, load cell and fascia. -
FIG. 20A is a front perspective view of an embodiment of a frame of the deterioration resistant mass confinement cell ofFIG. 19 . -
FIG. 20B is a back perspective view of an embodiment of a frame of the deterioration resistant mass confinement cell ofFIG. 19 . -
FIG. 20C-E are top, front and side views of an embodiment of a frame of the deterioration resistant mass confinement cell ofFIG. 19 . -
FIG. 21 is a perspective view of one embodiment of the frame of the deterioration resistant mass confinement cell ofFIG. 19 positioned in a flat configuration. -
FIG. 22A is a front perspective view of an embodiment of a load cell of the deterioration resistant mass confinement cell ofFIG. 19 . -
FIG. 22B is a back perspective view of an embodiment of a load cell of the deterioration resistant mass confinement cell ofFIG. 19 . -
FIG. 23A is a front view of one embodiment of a fascia that may be utilized with the deterioration resistant cells of the present invention. -
FIG. 23B is a back view of one embodiment of a fascia that may be utilized with the deterioration resistant cells of the present invention. -
FIG. 24A is a front view of one embodiment of a fascia that may be utilized with the deterioration resistant cells of the present invention. -
FIG. 24B is a back view of one embodiment of a fascia that may be utilized with the deterioration resistant cells of the present invention. -
FIG. 25A is a front view of one embodiment of a fascia that may be utilized with the deterioration resistant cells of the present invention. -
FIG. 25B is a back view of one embodiment of a fascia that may be utilized with the deterioration resistant cells of the present invention. -
FIG. 26 is an exploded view of one embodiment of a deterioration resistant mass confinement cell including a frame, enclosing bar and fascia. -
FIG. 26A is a front perspective view of an embodiment of the frame adjoined to the enclosing bar of the deterioration resistant mass confinement cell ofFIG. 26 in a folded assembly position. -
FIG. 26B is a front view of one embodiment of a fascia that may be utilized with the deterioration resistant cells of the present invention, such as the cell ofFIG. 26 . -
FIG. 27A is a front view of one embodiment of an end cap that may be utilized with the deterioration resistant cells of the present invention. -
FIG. 27B is a back view of one embodiment of an end cap that may be utilized with the deterioration resistant cells of the present invention. -
FIG. 28 is a front perspective view of one embodiment of a deterioration resistant mass confinement cell of the present invention that includes a frame, load cell, fascia and end caps. -
FIG. 29 is an exploded view of the deterioration resistant mass confinement cell ofFIG. 28 . -
FIG. 30 is a front perspective view of the deterioration resistant mass confinement cell ofFIG. 26 that further includes an adjoined geogrid. -
FIG. 31 is a front perspective view of the deterioration resistant mass confinement cell ofFIG. 28 that further includes an adjoined geogrid. -
FIG. 32 is a perspective view of one embodiment of a front panel including a partial top panel having a plurality of securing mechanisms. -
FIG. 33 is a perspective view of a top cover embodiment used to cap a deterioration resistant mass confinement cell. -
FIG. 34 is a perspective view of bottom cover embodiment used to seal a deterioration resistant mass confinement cell. -
FIG. 35 depicts a top view of a deterioration resistant retaining wall row that includes a plurality of cells that have interlocking pegs and hinges. -
FIG. 36 depicts an exploded perspective view of an embodiment of an interlocking mechanism used with the deterioration resistant mass confinement cell that includes pegs and hinges. -
FIG. 37 depicts a perspective view of an embodiment of an interlocking mechanism use with the deterioration resistant mass confinement cell of the present invention that is a clipping device. -
FIG. 38 depicts a perspective view of an embodiment of an interlocking mechanism use with the deterioration resistant mass confinement cell of the present invention of the present invention that is an integral hook. -
FIG. 39 depicts a perspective view of an embodiment of a deterioration resistant mass confinement cell including a structural stabilization grid. -
FIG. 40 depicts a front perspective view of one embodiment of a polygonal cell cap that may be utilized with various embodiments of the present invention. -
FIG. 41 depicts an exploded view of one embodiment of a cell cap that may be utilized with various embodiments of the present invention. -
FIG. 41A is a perspective view of one top cap embodiment of the cell cap ofFIG. 41 . -
FIG. 41B is a perspective view of one top cover embodiment of the cell cap ofFIG. 41 . -
FIG. 41C is a back perspective view of an end cap embodiment of the cell cap ofFIG. 41 . -
FIG. 41D is a front perspective view of an end cap embodiment of the cell cap ofFIG. 41 . -
FIG. 42 depicts a perspective view of one embodiment of a cell cap that may be utilized with various embodiments of the present invention. -
FIG. 43 depicts a perspective view of one embodiment of a cell cap that may be utilized with various embodiments of the present invention. -
FIG. 44 a is a perspective top view of one embodiment of an edger that may include the surface coating or lamination of the present invention. -
FIG. 44 b is a perspective bottom view of one embodiment of an edger that may include the surface coating or lamination of the present invention. -
FIG. 45 a is a perspective top view of one embodiment of a paving stone that may include the surface coating or lamination of the present invention. -
FIG. 45 b is a perspective bottom view of one embodiment of a paving stone that may include the surface coating or lamination of the present invention. - The embodiments of the present invention described below are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Rather, the embodiments are chosen and described so that others skilled in the art can appreciate and understand the principles and practices of the present invention.
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FIGS. 1 and 2 depict one embodiment of the deterioration resistantmass confinement cell 10 comprising aframe 12, including aback panel 14 and one ormore side panels 16, and achamber enclosing member 18. In this embodiment of the present invention the enclosingmember 18 is a front panel that forms theconfinement cell 10 when joined with theframe 12. Theside panels 16 of this embodiment operably join the enclosingmember 18 to theframe 12 to form theconfinement cell 10 having acontinuous flow chamber 20. Thecontinuous flow chamber 20 is positioned within theframe 12 and enclosingmember 18. - It is noted that various embodiments of the
mass confinement cell 10 of the present invention include no top panel or a partial top panel and no bottom panel or a partial bottom panel. The assembly of a retaining wall with a plurality ofsuch confinement cells 10, which include an open top and bottom, allows for the flow and/or comingling of fill material from adjacent cells positioned above and/or below through each cell's 10continuous flow chamber 20. In various embodiments, the bottom panel may include one or more apertures to allow for at least a partial alignment of openings, thereby allowing the flow and comingling of fill material from one confinement cell to cells positioned above and/or below. - Various embodiments of the present invention (e.g. as depicted in
FIGS. 1 and 2 ) are a mass confinement cell that includes aframe 12 and enclosingmember 18 having a panel design. Generally, themass confinement cell 10 of such embodiments include aframe 12 and/or enclosingmember 18 having two or more panels that are operably connected with one ormore securing mechanisms 22 to join the two or more panels, thereby forming theframe 12 and/or enclosingmember 18. In other embodiments, themass confinement cells 10 require securingmechanisms 22 to join three or more panels to form theframe 12 and/or enclosingmember 18. Also, in still other embodiments, themass confinement cells 10 of the present invention require securingmechanisms 22 to join four or more separated panels to form theframe 12 and/or enclosingmember 18. In many of these embodiments, theframe 12 and/or enclosingmember 18 includeside panels 16 that are operably joined to afront panel 12 and/orback panel 14. In such embodiments, theside panels 16,front panel 12 and backpanel 14 may be adjoined with two ormore securing mechanisms 22 to form acontinuous flow chamber 18 within themass confinement cell 10. - In various embodiment of the present invention, a
front panel 24 of thecell 10 may be flat, rounded or beveled. For example,FIGS. 3 a and 3 b depicts achamber enclosing member 18 of thecell 10 as depicted inFIGS. 1 and 2 having afront panel 24. Thefront panel 24 of this embodiment may include a beveled front having one or more bends, slants or creases in thefront panel 12.FIGS. 3 a and 3 b depict a beveled front that takes on a tri-panel appearance. It is noted that thefront panel 24 may also be rounded, substantially flat or includes positions of relief rather than beveled to provide a more natural appearance. - The enclosing
member 18 of this embodiment further includes thefront panel 24 and aback surface 26 that are separated by one ormore ribs 28 to adjoin and provide support and stability to thefront panel 24 and backsurface 26. Alternatively, a corrugated or waved ribbing system (not shown) may separate thefront panel 24 and back surface 26 rather than straight ribs to provide pressure absorption means to remove the pressure of the fill material on thefront panel 24. The enclosingmember 18 of this embodiment further includes at least part of one ormore securing mechanisms 22. As will be explained further below, thefront panel 24 may display an earthen appearance or other color and design that may be molded into the surface or applied to the surface. -
FIGS. 4 a and 4 b depict one embodiment of aback panel 14 that includes aninside surface 30 and anouter surface 32 adjoined and separated byribs 28. Theback panel 14 of this embodiment is the back panel ofFIGS. 1 and 2 . Theback panel 14 of this embodiment may also include one or moreside panel stoppers 34. Theside panel stoppers 34 assist in locating theside panels 16 in position for adjoining the enclosingmember 18 to theside panels 16 during assembly of theconfinement cell 10.FIGS. 4 a and 4 b further depict the sockets of one ormore securing mechanisms 22 that are intended to receive pins or pegs that are intended adjoin theback panel 14 to theside panels 16 of this embodiment. -
FIG. 5 depicts one embodiment of aside panel 16 of themass confinement cell 10 illustrated inFIGS. 1 and 2 . Thisside panel 16 includes andinner surface 30 and anouter surface 32, which are adjoined and separated byribs 28. Theside panel 16 of this embodiment also includes pegs of the securingmechanisms 22 that may be inserted into the sockets of the enclosingmember 18 and backpanel 14. It is noted that the pegs and sockets of the securingmechanisms 22 can be interchanged on any of the panel structures. -
FIG. 6 depicts one embodiment of aframe 12 of the present invention wherein theside panels 16 are adjoined to aback panel 14. In this embodiment, theside panels 16 and backpanel 14 may be secured together with the securingmechanisms 22 so as to allow for the side panels and back panel to at least partially swivel on the securingmechanisms 22. Such a configuration provides advantages in storage and transportation in that theside panels 16 and backpanel 14 can be placed in a flattened configuration as depicted inFIG. 6 and then angled upon assembly as depicted inFIG. 7 . It is noted that in various embodiments thefront panel 12 may also be secured to one of theside panels 16 and placed in the flattened configuration for storage and transportation or may be a separate component that is adjoined upon assembly as is depicted inFIG. 8 . Alternatively, a stabilizing partition (not shown) may be adjoined to aside panel 16 when theblock 10 is in a flat configuration. Upon assembly, the stabilizing partition may be adjoined to theother side panel 16 to form thechamber 18. Once the chamber is formed thechamber enclosing member 18 may be secured to theside panels 16 to form this embodiment of the confinement cell. Such embodiments allow for thechamber enclosing member 12 to be changed later in time while maintaining the integrity of the wall and maintenance of the fill material within the confinement cell during the replacement process. - The mass confinement cell embodiments depicted in
FIGS. 1-9 c and the other embodiments of the present invention are especially advantageous for mega-cell products of sizes equal to or greater than one foot in height, two feet wide and one foot deep (e.g. at least about 1.5 feet in height, 3 feet wide and 1.5 feet deep or 1 foot in height, 2 feet wide and 1.5 feet deep). Such large confinement cells allow for easy storage and transportation of such mega-cells by allowing them to flatten, thereby decreasing the space needed for large numbers of cells. - As previously mentioned, various embodiments of the
mass confinement cell 10 generally include one ormore securing mechanisms 22 that provide a sufficient means for securing the separated panels to each other. A sufficient means is generally one wherein the securingmechanisms 22 will not release when the force of the fill material is applied to the panels and enclosingmember mass confinement cell 10.FIGS. 9 a-9 c depict one embodiment of asecuring mechanism 22 that may be utilized to form one embodiment of amass confinement cell 10 of the present invention.FIG. 9 a depicts the embodiment illustrated inFIGS. 1 and 2 , wherein theconfinement cell 10 includes an enclosingmember 18 and backpanel 14 adjoined to twoside panels 16 with securingmechanisms 22.FIGS. 9 b and 9 c depict one embodiment of asecuring mechanism 22 utilized to adjoin the panels of theconfinement cell 10 of the present invention. In this embodiment, the securingmechanism 22 includes a peg and socket system including apeg 36 having a base 38 and two or moreelongated keys 40 extending upward from thebase 38. In some embodiments, thekeys 40 may include a beveled top that allows for thekeys 40 to be inserted into asocket 42 and lock the panels into place when completely inserted. - Other embodiments of securing mechanisms that may be utilized in the present invention include the peg and socket systems (threaded, integrated and non-integrated), T-hook and T-slot, locking snaps, hinges and other mechanisms that would adjoin and secure the panels into the confinement cell configuration. Examples of some securing mechanisms are disclosed or suggested in U.S. application Ser. No. 11/126,546 filed on May 11, 2005, and U.S. Provisional Application Ser. No. 60/707,032, filed on Aug. 10, 2005, the contents of which are incorporated by reference herein.
-
FIGS. 10 and 11 depict another embodiment of themass confinement cell 10 of the present invention wherein thecell 10 includes aframe 12 that is adjoined to achamber enclosing member 18 to form a fillingchamber 20. Similar to the embodiments previously described, theframe 12 of this embodiment includes twoside panels 16 and aback panel 14 that are hingedly adjoined so as to maneuver to either a flat or assembly position. Such embodiments allow for the back andside panels side panel member 18 or aback panel 14 by securing the pieces together with one ormore securing mechanisms 22. - The various mass confinement cell embodiments may further include one or more
interior partitions 44. Theinterior partitions 44 may also be utilized to add additional support to theconfinement cell 10 to prevent any possible crushing or expansion of thecell 10.FIG. 10 depicts one confinement cell embodiment wherein theinterior partition 44 is positioned in thechamber 20 of thecell 10 and is present to define separate chambers that can accommodate filling of eachindividual chamber 18 with appropriate fill material, such as sand, gravel, crushed rock, pea rock, soil, cement, concrete or any other suitable material. Theinterior partitions 44 may be secured to thefront panel 12, backpanel 14 or to the twoside panels 16 utilizing one or more securing mechanisms (e.g. peg and socket systems, T-hook and T-slot systems, panel slot systems and other securing means). Alternatively, the interior partitions may be secured to the opposing panels utilizing other adjoining means, such as screws, rivets, hooks, adhesives or any other materials to adequately adjoin the opposing panels. -
FIGS. 11 a and 11 b depict interior and exterior views of one embodiment of an interior partition. Theinterior partition 44 of this embodiment generally includes asheet 46 havingpanel attachments 48 at each end that can butt against and accommodate securing of the partition to a panel. As previously mentioned, any securing or adjoining means may be utilized to adjoin theinterior partition 44 to the enclosingmember 18, backpanel 14 orside panels 16. To further stabilize theinterior partition 44, thepartition 44 may also include one ormore ribs 28 that extend between thepanel attachments 48 or extend from the top to the bottom of theinterior partition 44 in a vertical direction. - Additionally,
multiple chambers 20 andpartitions 44 also allow for themass confinement cell 10 to be cut into various shapes or into partial cells and still maintain achamber 20 that can receive and retain fill materials. The ability to cut the retainingcells 10 and still retain the same features is particularly useful in preparing ends and awkward segments of retaining walls. In one embodiment, aconfinement cell 10, as depicted inFIG. 10 , may be cut to a desired width, and adjoined with apartition 44 positioned on the enclosingmember 18 and backpanel 14 to thereby secure the enclosingmember 18 to theback panel 14 of thecell 10 at approximately the points where they were cut. -
FIG. 12 depicts an exploded view of the mass confinement cell ofFIG. 10 , thereby illustrating the assembly of this embodiment of the present invention. In this embodiment, the enclosing member includes twosockets 42 that are adapted to accept twopegs 36 that are adjoined to the twoside panels 16. In some embodiments, thepegs 36 may be polygonal in shape and thesocket 36 circular in shape to thereby enhance the attachment of the enclosingmember 18 to theframe 12 when thepegs 36 are inserted into thesockets 36. Furthermore, one ormore partitions 44 may be positioned in thecell 10 to added additional stability to the confinement cell or to provide an outer panel when cutting. - The various embodiments of the present invention may also include one or
more pins 50 that may be inserted into apertures in thesecuring mechanism 22 or slots (not shown) positioned anywhere on the confinement cell to further secure the cell into position in a retaining wall and also may secure the confinement cell to geogrid that is positioned between the rows of cells in a wall.FIG. 12 depicts one embodiment of thepins 50 that may be utilized with the present invention. - The various mass confinement cell embodiments of the present invention may further include one or more positioning flanges or setting
extensions 52 as depicted inFIG. 12 . On a constructed wall, each retaining flange or settingextensions 52 are wall retention devices that operate to assist in placing the confinement cell in the proper position during wall assembly and also inhibits outward movement of the wall once constructed. Normally, the retaining flange or settingextensions 52 extend downward from the back of theback panel 14 and rest against the back of the mass confinement cell orcells 10 located below. In other embodiments, the flange or settingextensions 48 may also extend downward from the enclosing member orfront panel 18,side panels 16 or aninterior partition 44.FIG. 13 depicts one embodiment wherein the settingextensions 52 extend downward from thepartition 44. The retaining flange or settingextension 52 may be a unitary piece extending downward or upward from themass confinement cell 10 or a series of fingers extending downward or upward from theconfinement cell 10. It is also noted that the settingextensions 52 may further be utilized to anchor the confinement cell into the fill material below, thereby inhibiting movement of the cell upon filling. - As previously disclosed in FIG. 13., various embodiments of the present invention may include a stabilizing
partition 44 that may be utilized to further stabilize the cell structure, take pressure off of the front panel caused by the packed fill material and also provide a divider so that different fill materials may be added to the same cell 10 (e.g. a packing material toward the back of the confinement cell and a planting fill material in the front of the cell). In some embodiments, as previously mentioned, thepartition 44 may includepeg extensions 52 that operate as a cell positioning and securing means when constructing a retaining wall. Thepeg extensions 52 may be placed anywhere on thepartition 44 including the ends and/or dispersed along the bottom edge of thepartition 44. In construction of a wall, thepeg extensions 52 may butt up against one or more partitions present in blocks positioned below, thereby holding theconfinement cell 10 in position and providing an indication of proper positioning of thecell 10. It is noted that thepeg extensions 48 may be included on thefront panel 24, backpanel 14 orside panels 16 rather than or in addition to thepartition 44 so as to butt up against thefront panel 24, backpanel 14 orpartitions 44 of the confinement cells positioned below. - In another embodiment of the present invention, as depicted in
FIGS. 14-18B , the deterioration resistantmass confinement cell 10 comprises aframe 12, including afront panel 24 operably adjoined to one ormore side panels 16, achamber enclosing member 18 and afascia 54. In various embodiments, theframe 12 is folded into an assembly configuration and the enclosingmember 18 is next secured to the one ormore side panels 16, thereby joining thefront panel 24 and enclosingmember 18 to form aconfinement cell 10 having acontinuous flow chamber 20. Thecontinuous flow chamber 20 is positioned within theframe 12 and enclosingmember 18. - Similar to the embodiments depicted in
FIG. 1 , the mass confinement cells, of this embodiment, include no top panel or a partial top panel and no bottom panel or a partial bottom panel. When a plurality ofconfinement cells 10 are positioned in proximity to each other in a wall structure, the open top and bottom allows for the flow and/or comingling of fill material from one cell to adjacent cells above and/or below through thecontinuous flow chambers 20. - The
mass confinement cell 10, as depicted inFIGS. 14-18B , includes two ormore side panels 16 that are operably adjoined with thefront panel 24 and enclosingmember 18 by one ormore securing mechanisms 22, thereby forming themass confinement cell 10. It is noted that themass confinement cell 10 may require securingmechanisms 22 to join three or more panels, or four or more panels, to form themass confinement cell 10 of the present invention. - In various embodiments of the present invention, the
front panel 24 of thecell 10 may be flat, rounded or beveled to accommodate molding or fabrication (e.g. lamination, painting, U.V. Coating) to provide the desired earthen appearance or aesthetic design. However, in other embodiments afascia 54 may be secured to thefront panel 24 to provide the desired appearance. It is noted that in various embodiments of the present invention, thefront panel 24 orfascia 54 may also be beveled, rounded, substantially flat or include positions of relief to provide a more natural appearance. - As depicted in FIGS. 14 and 15A-B, the
front panel 24,side panels 16 and enclosingmember 18 of this embodiment generally include one ormore ribs 28 on the back side to provide additional support and stability. It is noted that theribs 28 may be positioned on the front side of thepanels member 18 to provide the enhanced support and stability. As previously mentioned, thefront panel 24 further includes at least part of one ormore securing mechanisms 22. As will be explained further below, thefront panel 24 orfascia 54 generally will display an earthen appearance or other design that may be molded into the front or exposed surface or the appearance or design may be fabricated or applied to the surface in a secondary operation. - Similar to the embodiment of
FIG. 1 , theframe 12 may be transported in a flat configuration.FIGS. 16A-16D depict an embodiment of theframe 12 that is positioned in a flat configuration. In such embodiments, one or more of theside panels 16 are adjoined to thefront panel 24 or back panel (not shown) with one ormore securing mechanisms 22. In this embodiment, theside panels 16 are adjoined to thefront panel 24 with living hinges 56, which comprise a thin flexible plastic (e.g. HDPE) that can bend into position without breaking when folding theframe 12 in assembly position to secure the enclosingmember 18. - As previously mentioned, various embodiments of the
mass confinement cell 10 depicted inFIG. 14 include one ormore securing mechanisms 22 havingsnaps 58 that rigidly secure theside panels 16 to thefront panel 24 when folded into assembly position. Thesnaps 58, in this embodiment, are attached to theside panels 16 to engage and lock thefront panel 24 andside panels 16 into assembly position. Thesepanels snaps 58 throughsnap apertures 60, which are located on thefront panel 24. Other securing mechanisms may be utilized in these embodiments, some of which are identified within. -
FIGS. 17A and 17B depict one embodiment of achamber enclosing member 18 that may be secured to theframe 12 ofFIGS. 16A-16D . The enclosingmember 18 may includeribs 28 that can be positioned on the front or back of the enclosing member to provide additional stability. In this embodiment, the enclosingmember 18 further includes asecuring mechanism 22 that is alarger snap 58 that may be inserted into anaperture 60 positioned on theside panels 16 when securing the enclosingmember 18 to theframe 12. - Various embodiments of the enclosing
members 18 further include one or more anchoring devices that may be utilized to position and secure eachcell 10 when assembling a wall and may also function to reduce or prevent overturn of the cells upon filling and compacting the fill material. One embodiment of such anchoring devices is depicted inFIG. 17B in the form ofpeg extensions 52. In this embodiment, thepeg extensions 52 are designed to fit in one or more peg extension slots orridges 62 positioned on the twocells 10 located below when constructing a wall, revetment or other earth retention system. - Embodiments of the present invention may include one or more fascia that is adjoined to the frame or enclosing member to provide the desired appearance or design.
FIGS. 18A and 18B depict one embodiment of afascia 54 that may be utilized with the confinement cells of the present invention. Further explanation of fascia design will be discussed below. - It is further noted that the mass confinement cell embodiments depicted in
FIG. 14 may further include a load cell positioned within thefront panel 24,side panels 16 and enclosingmember 18. A further description load cell embodiments is described below. - The mass confinement cell embodiments depicted in
FIG. 14 is also especially advantageous for mega-cell products of sizes equal to or greater than one foot in height, two feet wide and one foot deep (e.g. greater than one-two feet in height, two-four feet wide and one-two feet deep). Such large confinement cells allow for easy storage and transportation of such mega-cells by allowing them to flatten, thereby decreasing the space needed for large numbers of cells. - In yet another embodiment of the present invention, as depicted in
FIG. 19 , the deterioration resistantmass confinement cell 210 comprises aframe 212 operably adjoined to aload cell 202 and anaesthetic fascia 254. Theframe 212 of this embodiment generally includes afront panel 224 operably adjoined to one ormore side panels 216. Theload cell 202 may include aback panel 214 and secures to one or more of theside panels 216 to join theframe 212 to theload cell 202, thereby forming acontinuous flow chamber 220 in themass confinement cell 210. Thecontinuous flow chamber 220 is generally positioned within theframe 212 andload cell 202. -
FIGS. 20A-E depict one embodiment of aframe 212 in a folded or assembly position, thereby being prepared formass confinement cell 210 assembly. As previously suggested, theframe 212 generally includes afront panel 224 operable adjoined to one ormore side panels 216 by one or more securing mechanisms 222 (e.g. living hinges, snaps, pegs and pins). - Similar to the embodiments depicted in the paragraphs above, the
mass confinement cells 210 of this embodiment include no top panel or a partial top panel and no bottom panel or a partial bottom panel. When a plurality ofconfinement cells 210 are positioned in proximity to each other in a wall structure, the open top and bottom allows for the flow and/or comingling of fill material from one confinement cell to adjacent confinement cells above and/or below through thecontinuous flow chambers 220. - In various embodiments of the present invention, the
front panel 224 of theconfinement cell 210 may be flat, rounded or beveled by molding or by a secondary fabrication process to provide the desired earthen appearance and/or design. However, in other embodiments afascia 254, as depicted inFIG. 19 , is secured to thefront panel 224 to provide the desired appearance. It is noted that thefront panel 224 orfascia 254 may also be beveled, rounded, substantially flat or include positions of relief to provide a more natural earthen appearance or desirable design. - As depicted in
FIGS. 20A-E , thefront panel 224 andside panels 216 of theframe 212 of this embodiment may include one ormore ribs 228 on its front or back side to provide support and stability to thefront panel 224 andside panels 216. As previously mentioned, thefront panel 224 andside panels 216 further include at least part of one ormore securing mechanisms 222. As will be explained further below, thefront panel 224 orfascia 254 generally will display an earthen appearance or other desirable design that may be molded into the front or exposed surface or may be fabricated and/or applied to the surface. - The
front panel 224 may further include one or moreload bearing members 204. Theseload bearing members 204 are configured to take pressure off thefascia 254 when a wall is assembled, thereby allowing for greater ease in removal and replacement when desired. Thefront panel 224 orfascia 254 may further include one or more side flaps (not shown) positioned on the outer edges of thefront panel 224 orfascia 254. The side flaps are generally flexible, textured and colored to hide the gaps between thevarious cells 210 placed in a wall and to assist in the reduction of fine fill material moving through the face of the wall. - In various embodiments of the present invention, as depicted in
FIGS. 20A-E , theside panels 216 further include one ormore grid fasteners 206, wherein geogrid can thread over and secure when utilized between rows ofconfinement cells 210. In other embodiments, thegrid fastener 206 may include an overhanging portion (not shown) that the grid can slide under, thereby inhibiting vertical movement of the grid once in position. Theside panels 216 may further include lighteningapertures 208.Such apertures 208 provide structure by allowing the fill material to flow through the apertures, thereby further locking the frame into the slope. Theapertures 208 further allow for reduction of resin and thereby make the product more light-weight and cost efficient. The lighteningapertures 208 may further be utilized to adjoin side caps and other accessories desired to complete a wall. - The
side panels 216 may further include one or more anchoring devices that may be utilized to position eachcell 210 when assembling a wall and may also function to reduce or prevent overturn of the cells upon filling and compacting of fill material. One embodiment of the anchoring devices, as depict inFIGS. 20A-E , are in the form ofpeg extensions 252. In this embodiment, thepeg extensions 252 are designed to insert under an anchoring ridge 262 or in an anchoring aperture positioned on the twoload cells 202 located below in a wall, revetment or earth retention system. - Similar to the embodiment of
FIGS. 1 and 14 , theframe 212 of this embodiment may be transported and stored in a flat configuration.FIG. 21 depicts an embodiment of theframe 212 that is positioned in a flat configuration. In such embodiments, one or more of theside panels 216 are adjoined to thefront panel 224 with one ormore securing mechanisms 222. In this embodiment, theside panels 216 are adjoined to thefront panel 224 with living hinges 209 and retention snaps. The living hinges 209 generally comprise a thin flexible material, such as plastic (e.g. HDPE, LDPE, polypropylene), that can bend into position without breaking when folding theframe 212 into assembly position to secure theload cell 204. Other securing members may be utilized to secure the panels of the frame (e.g. peg and sockets and mechanical hinges). It is noted that in other embodiments, the frame may be reversed, wherein the side panels are adjoined to a back panel of the confinement cell. Another embodiment may include a separate front panel or a securing mechanism to attach a fascia to the ends of the side panels or to the front of the load cell if it was desired to reverse the configuration of the confinement cell. - As previously mentioned, various embodiments of the
frame 212 depicted in previously described FIGS. include one ormore securing mechanisms 222 that secure theside panels 216 to thefront panel 224 and/or back panel (not shown) when folded into assembly position. The securingmechanisms 222, in the embodiment depicted inFIGS. 14-21 , includesnaps 258 that are attached to theside panels 216 and engage and lock thefront panel 224 into assembly position by passing thesnaps 258 throughsnap apertures 260 located on thefront panel 224. Other securingmechanisms 222 may be utilized in these embodiments, some of which are identified within. -
FIGS. 22A and 22B depict one embodiment of aload cell 204 that may be secured to theframe 212 by one or moreload cell fasteners 205. Generally, theload cell 204 is a cylinder that when attached to theframe 212 forms at least a portion if not all of thecontinuous chamber 220 of themass confinement cell 210. In this application a cylinder may comprise a cylinder that includes a circular or elliptical structure and may also include a structure that has one or more substantially straight sides and one or more rounded sides. In the embodiments ofFIGS. 22A and 22B theload cell 204 includes a substantiallystraight back panel 214 integrally adjoined to arounded front section 215. Theback panel 214 further includesribs 228 that may be position on the front and/or back of theback panel 214 to provide additional stability. Theload cell 204 may further include ananchoring ridge 217 or aperture (not shown) that may be utilized to accept the anchoring devices (e.g. peg extensions) forconfinement cell 210 positioning and overturn prevention or reduction. - The
load cell fasteners 205 may be any fastening device or material that securely adjoins theload cell 204 to theframe 212. In one embodiment, as depicted inFIGS. 22A and 22B theload cell fastener 205 is one or more projections that extend inward from the outer edge of the anchoringridge 217. In operation, theload cell 204 is inserted over and into theframe 212 so that theload cell fastener 205 engages with aload cell aperture 207 or ridge on theside panels 216 of theframe 212. In other embodiments there may include two or moreload cell fasteners 205 orload cell apertures 207 that may be utilized as set-back devices when positioning theconfinement cells 210 in the wall structure. For example, aload cell fastener 205 orload cell apertures 207 may be positioned in front of a secondload cell fastener 205 orload cell apertures 207 on theload cell 204 orside panels 216 to provide a set back of the confinement cells at 3 mm and 1.25 cm. Set back positions generally allow for a wall to be constructed in a vertical configuration or angled back into the slope. The set back positions of the load cell fasteners may be at any distance desired to provide the desired wall angle. Another alternative to multiple set-back positions would be to manufactureseparate load cells 204 with different attachment points for set back rather than having multiple fasteners positioned on theload cells 204 and/orside panels 216. - The
load cell 204 may further include one ormore grid fasteners 206 for securing and positioning geogrid when it is utilized in a wall structure. Thegrid fastener 206 is configured to be inserted in an aperture of the geogrid and positioned over the geogrid at connection so that the grid does not move in a vertical direction once it is applied. - Additionally, in other embodiments, the
load cell 204 may be split in two or more sections, wherein one section nests with the other section. The two nested sections allows for the compression of the sections together to make a smaller load cell that may be utilized when secured to a cut frame for partial confinement cells. In such embodiments, the two sections would further include a fastening device to fixedly secure the two sections together when the proper size is achieved, thereby preventing movement of the two sections of the load cell. - Various embodiments of the present invention may also include a fascia with the desired aesthetic appearance, rather than having the aesthetic appearance (e.g. texture and color) molded into the front face of the
front panel 12.FIGS. 23A and 23B depict a front and back view of one embodiment of afascia 254 that may be utilized with the confinement cells of the FIGS. described herein. Further explanation of fascia design and manufacture will be discussed below. Thefascia 254 in various embodiments of the present invention may include a plurality ofribs 228 to add stability and structure to thefascia 254. It is noted that the top panel of thefascia 264 may include one ormore indentations 266 to accommodate and alternate between theload bearing members 204 upon administering thefascia 254 to thefront panel 224. -
FIGS. 24A and 24B depict another embodiment of afascia 254 that may be utilized with any embodiment of the present invention. Generally, thefascia 254 includes afront panel 268, a partialtop panel 270 and one ormore fascia fasteners 272. Thefascia 254 may also optionally include wrap around sides 274, that wrap around the side panels and bottom panel upon assembly. Each of these panels may be textured and include color and/or other additives (e.g. U.V. inhibitor) to provide an earthen appearance, crystalline appearance or any other aesthetic design. Additionally, such fascia may be prepared utilizing any of the techniques discussed below or those known in the art for forming the desired appearance.FIGS. 25A and 25B depict another embodiment of afascia 254 of the present invention, wherein thefascia 254 also includes a partialbottom panel 276. In all of the embodiments of the present invention that include afascia 254, thefascia 254 may be permanently fixed to theframe 212 or may be removable so as to be replaced when damaged or a change is desired. - In various embodiments of the
mass confinement cells 10 of the present invention, the surface visible to the observer, such as thefront panel 224 orfascia 254 of themass confinement cell front panel 224 orfascia 254, will have a natural earthen appearance simulating the texture and color of natural earthen surfaces. For example in some embodiments, the exposed surface of thefront panel 224 or the surface of thefascia 254 may be textured and colored to have the appearance of rock, natural stone, sand, soil, clay, wood, trees and foliage, water, or any other natural earthen appearance. In other embodiments, thefront panel 224 orfascia 254 will have a crystalline appearance or will have another aesthetically appealing design. Additionally, in other embodiments, the exposed surface of the landscaping product, such as thefront panel 224 orfascia 254, may further include one or more designs (e.g. symbols, company names, logos, images) that may be positioned in the natural earthen appearance texture and color, crystalline texture and color or other design (e.g. a company logo embedded in a stone color and texture). Also, in other embodiments of the present invention, thefront panel 224 orfascia 254 may further include a design, such as the appearance of multiple bricks, stones, or blocks. This allows for the installation of larger mass confinement cells (e.g. mega-cells) in a wall that appears to include a multitude of bricks, stones, blocks, timbers and the like. - In various embodiments of the present invention the texture and/or front surface of the
front panel fascia -
FIG. 26 depicts another embodiment of the mass confinement cell 310 of the present invention wherein the enclosingmember 318 includes one or more enclosing bars 319 that are adjoined to theside panels 316 of theframe 312 to form the chamber 320.FIG. 26A depicts one embodiment of theframe 312 and enclosingmember 318 wherein the enclosing bars 319 of the enclosingmember 318 further include ananchoring ridge 317 for setting and securing the settingextensions 352 of each of the cells positioned above. The enclosing bars 319 may further include a lighteningaperture 308 positioned in the interior of asingle bar 319 or the enclosingmember 318 may comprise two or more bars 319 (not shown) wherein a gap is present between the two or more bars. The enclosingmember 318 of the embodiment ofFIG. 26 may be adjoined to theframe 312 with one or more securing mechanisms that adequately secures themember 318 to theframe 312. For example the enclosingmember 318 may be adjoined to theframe 312 by one or more snaps positioned on the enclosingmember 318 engaging one or more snap apertures positioned on theframe 318. A similar snap and snap aperture securing mechanism is depicted inFIGS. 14-17B . - The cell embodiment depicted in
FIG. 26 further includes afascia 354 as shown in 26B. Thefascia 354 may include afront panel 324 having an earthen texture and color (e.g. stone, wood, rock) or any other aesthetic design molded, fabricated or applied to the visible surface. It is noted that in other embodiments of the present invention the front panel having an earthen texture and color or other aesthetic design may be integral with the frame rather than part of an attachable fascia. In various embodiments, the fascia may overlap the frame as depicted in the FIGS above or may nest within afascia frame 321 as depicted inFIG. 26 . As depicted inFIG. 26B thefascia frame 321 includes aridge 323 that surrounds a nestedfascia 354 and functions similar to a picture frame. Thefascia frame 321 may be any color and in some embodiments may have the color and appearance of grout. In other embodiments of the present invention, a confinement cell may include more than one fascia frame wherein multiple fascias may be nested in each separate frame. In various embodiments the multiple fascia frames may provide the appearance of multiple stones positioned in a single mass confinement cell. - The
mass confinement cell end cap 278 to finish the end of a wall, provide an end finish for a sharp turn (e.g. 90° turn) in the wall or to accommodate a partial confinement cell when a confinement cell must be cut for fitting. A front and back view of one embodiment of anend cap 278 is depicted inFIGS. 27A and 27B . In most embodiments, theend cap 278 will include aback surface 280 andside surface 282 that is textured and colored similar to thefront panel 224 orfascia 254 of themass confinement cell 210. Additionally, thetop surface 284 of theend cap 278 may include a texture and color similar to thefront panel 224 orfascia 254 of themass confinement cell 210. In one embodiment, as depicted inFIG. 27B , theend cap 278 includes one or more securing pegs 286 that may be inserted into the lighteningapertures 208 of theside panels 216. Theend cap 278 may also includeribs 228 to provide stability to the structure. -
FIG. 28 depicts one embodiment of a fully assembledmass confinement cell 210 that includesend caps 278.FIG. 29 depicts an exploded view of the components of themass confinement cell 210 depicted inFIG. 28 including aframe 212,load cell 204,fascia 254 and twoendcaps 278.FIGS. 30 and 31 depict two embodiments of theconfinement cell 210 of the present invention accommodating the securing of eachcell 210 withgeogrid 288. - The mass confinement cell embodiments depicted in previously disclosed FIGS. and the embodiments of the present invention are also especially advantageous for mega-cell products of sizes equal to or greater than one foot in height, two feet wide and one foot deep (e.g. greater than 2 feet in height, four feet wide and two feet deep) and multi-cell products (e.g. products that appear like multiple individual units that are approximately 3-36 in height, 2-4 feet wide and 9 inches to 4 feet deep) that are advantageous for the mass consumer market. Such large confinement cells and multi-unit cells allow for easy storage and transportation of such mega-cells and multi-cells by allowing them to flatten, thereby decreasing the space needed for large numbers of cells. In some embodiments of the
confinement cells 210 of the present invention, a plurality ofload cells 204 may be adjoined together and secured to the larger frame to reduce the flow forces of the fill materials in the larger walls. The load cells of the multi-cell embodiments may be adjoined with tabs that may be separated to curve the wall when desired. Furthermore, the multi-cell embodiments of the present invention may be utilized to install large sections of wall with few components and still provide the appearance of a multitude of individual cells. - In many embodiments of the present invention, the appearance of the
front panel fascia mass confinement cell confinement cell front panel fascia mass confinement cell mass confinement cell confinement cell front panel fascia cell - In other embodiments of the present invention, the earthen appearance or other design can be achieved through a lamination process. In various embodiments, a sheet of polymeric material including the desired color and additives (e.g. UV inhibitor, natural or synthetic stone particles . . . ) is laminated over the portions of the
mass confinement cell front panel fascia front panel fascia front panel fascia front panel fascia front panel fascia - In yet other embodiments of the present invention, the earthen appearance or aesthetic design may be achieved by utilizing a solid surface coating. The solid surface coating generally includes one or more natural mineral or fiber fillers, one or more polymeric binder resins and one or more initiators. The natural mineral or fiber fillers may include but are not limited to natural stone or rock filler (e.g. granite, marble, quartz, limestone, shale particles), wood fiber, hydrated alumina (e.g. aluminum trihydrate), ground silica, acrylic chips, calcium carbonate, aluminum oxide with pigmented polymer coated quartz, sand, and any other filler that would provide a natural earthen appearance.
- Various embodiments of the present invention include one or more polymerizable binder resins. In one embodiment, the present invention provides a system comprising initiators and one or more of the polymerizable binder resins, each binder resin bearing one or more polymerizable groups. In accordance with this embodiment, the photoinitiator group serves to initiate polymerization of the polymerizable groups, thereby forming a polymeric coating, e.g., in the form of a layer covalently bound to the support surface (e.g. block surface or landscaping product surface) of a desired article via the one or more initiators. As used herein, “polymerizable group” shall generally refer to a group that is adapted to be polymerized by initiation via free radical generation, and more preferably by photoinitiators activated by visible or long wavelength ultraviolet radiation.
- Suitable polymerizable compounds are selected from monomeric polymerizable molecules (e.g., organic monomers), and macromeric polymerizable molecules (e.g., organic macromers). As used herein, “macromer” shall refer to a macromolecular monomer having a molecular weight of about 250 to about 25,000, and preferably from about 1,000 to about 5,000. For purposes of the present invention, and unless specified otherwise, the term “monomer” when used in this respect shall generally refer to monomeric and/or macromolecular polymerizable molecules.
- In yet another embodiment, the polymerizable monomer compounds of the present invention comprise macromeric polymerizable molecules. Suitable macromers can be synthesized from monomers such as those illustrated above. According to the present invention, polymerizable functional components (e.g., vinyl groups) of the macromer can be located at either terminus of the polymer chain, or at one or more points along the polymer chain, in a random or nonrandom structural manner.
- Examples of some polymerizable binder resins that may be utilized in the present invention include, but are not limited to, polyurethanes, polyepoxides, epoxy-acrylates, epoxide and epoxy resins, urethane acrylates, methacrylates, unsaturated polyesters, polyols, acrylics and monomers and oligomers having similar backbone structures of these resins.
- The coatings also include one or more initiators. Generally the initiators are polybifunctional reagents of the invention carry one or more pendent latent reactive (e.g. photoreactive or thermoreactive) moieties covalently bonded to the resin. Various embodiments of the coatings of the present invention include one or more photoreactive moieties that are sufficiently stable to be stored under conditions in which they retain such properties. Latent reactive moieties can be chosen that are responsive to various portions of the electromagnetic spectrum, with those responsive to ultraviolet and visible portions of the spectrum (referred to herein as “photoreactive”) being particularly preferred.
- Photoreactive moieties respond to specific applied external stimuli to undergo active specie generation with resultant covalent boding to an adjacent chemical structure, e.g., as provided by the same or a different molecule. Photoreactive moieties are those groups of atoms in a molecule that retain their covalent bonds unchanged under conditions of storage but that, upon activation by an external energy source, form covalent bonds with other molecules.
- The photoreactive moieties generate active species such as free radicals and particularly nitrenes, carbenes, and excited states of ketones upon absorption of external electric, electromagnetic or kinetic (thermal) energy. Photoreactive moieties may be chosen to be responsive to various portions of the electromagnetic spectrum, and photoreactive moieties that are responsive to e.g., ultraviolet and visible portions of the spectrum are preferred and are referred to herein occasionally as “photochemical” moiety.
- Photoreactive aryl ketones, such as acetophenone, benzophenone, anthraquinone, anthrone, and anthrone-like heterocycles (i.e., heterocyclic analogues of anthrone such as those having N, O, or S in the 10-position), or their substituted (e.g., ring substituted) derivatives are utilized in some embodiments of the present invention. The functional groups of such ketones are preferred since they are readily capable of undergoing the activation/inactivation/reactivation cycle described herein. Benzophenone is one photoreactive moiety that may be utilized, since it is capable of photochemical excitation with the initial formation of an excited singlet state that undergoes intersystem crossing to the triplet state. The excited triplet state can insert into carbon-hydrogen bonds by abstraction of a hydrogen atom (from a support surface, for example), thus creating a radical pair. Subsequent collapse of the radical pair leads to formation of a new carbon-carbon bond. If a reactive bond (e.g., carbon-hydrogen) is not available for bonding, the ultraviolet light-induced excitation of the benzophenone group is reversible and the molecule returns to ground state energy level upon removal of the energy source. Photoactivatable aryl ketones such as benzophenone, thioxanthone, camphorpyinone and acetophenone are of particular importance inasmuch as these groups are subject to multiple reactivation in water and hence provide increased coating efficiency.
- Other initiators may include one or more photoinitiated reagents including four or more reactive groups. Examples of such initiators include tetrakis (4-benzoylbenzyl ether), the tetrakis (4-benzoylbenzoate ester) of pentaerythritol, and an acylated derivative of tetraphenylmethane.
- The azides constitute another class of latent reactive moieties and include arylazides (C6R5N3) such as phenyl azide and particularly 4-fluoro-3-nitrophenyl azide, acyl azides (—CO—N3) such as benzoyl azide and p-methylbenzoyl azide, azido formates (—O—CO—N3) such as ethyl azidoformate, phenyl azidoformate, sulfonyl azides (—SO2—N3) such as benzenesulfonyl azide, and phosphoryl azides (RO)2PON3 such as diphenyl phosphoryl azide and diethyl phosphoryl azide. Diazo compounds constitute another class of photoreactive moieties and include diazoalkanes (—CHN2) such as diazomethane and diphenyldiazomethane, diazoketones (—CO—CHN2) such as diazoacetophenone and 1-trifluoromethyl-1-diazo-2-pentanone, diazoacetates (—O—CO—CHN2) such as t-butyl diazoacetate and phenyl diazoacetate, and beta-keto-alpha-diazoacetates (—CO—CN2—CO—O—) such as t-butyl alpha diazoacetoacetate. Other photoreactive moieties include the aliphatic azo compounds such as azobisisobutyronitrile, the diazirines (—CHN2) such as 3-trifluoromethyl-3-phenyldiazirine, the ketenes (—CH═C═O) such as ketene and diphenylketene.
- The solid surface coating may be applied to the surface of the landscaping product of the present invention by any type of process that would provide substantial coverage of the product surface and secure attachment of the coating, such as spray coating, dip coating and the like. In various embodiments of the present invention, the solid surface coating may be administered to the product surface in a one step or two step process. For example, in a one step process, a substantially homogenous mixture of the filler, polymerizable resin and initiators are administered to the surface of the product and the initiators then subsequently activated to polymerize the resin and attach the coating to the surface.
- Alternatively, a two step or grafting process may be utilized to administer the solid surface coating. In such a process, the initiator is first administered to the surface and activated to attach the initiator to the surface. Once the initiator is attached, a substantially homogenous mixture of the filler and polymerizable resin is administered to the surface and the initiator is again activated to polymerize the resin and attach the mixture to the surface. It is noted that in various embodiments of the present invention, a tie-in layer may be applied to the surface to facilitate better attachment of the solid surface coating. For example, one or more layers, such as a silane, Plexar, Binel, siloxane and/or Parylene layer(s) may be applied to the surface prior to administration of the solid surface coating.
- In other embodiments of the present invention, the landscaping products, including the exposed components of the mass confinement cells (e.g. front panel, fascia, end cap, cell cap), may be colored and further textured utilizing a painting process. One such painting process that may be used with various embodiments of the present invention is a polymer adhesion painting process wherein a polymeric paint is adhered to the surface of the
mass confinement cell front panel fascia cell cap 114, has been flame treated or plasma treated. In one polymer adhesion painting method, the mass confinement cell is manufactured utilizing a process, such as injection molding, structural foam molding (e.g. low pressure multi-nozzle structural foam), rotomolding, thermoforming, extrusion or any other process. Next, all surfaces of the mass confinement cell intended to be painted are flame treated or plasma treated with an ion gun prior to applying paint. The flame treating may be performed with any gas torch system, such as propane, acetylene and the like. Plasma treatment may also be performed by any device that forms a gas plasma that can be directed to the polymeric surface. The flame or plasma treated surface should be painted within 24 hours, optionally within 8 hours and further optionally within 5 hours. Once the surface has been flame or plasma treated, a polymeric paint, such as a polyurethane paint, is mixed with a crosslinker and applied to the surface or surfaces of themass confinement cell - High Solids 3.5 V.O.C. two component polyurethane for metal, plastic, and interior wood. It is used for industrial and automotive applications. This system has excellent chemical and stain resistance. It has shown excellent adhesion to many substrates with good mar and abrasion resistance and it has 2-3 H hardness.
-
CHARACTERISTICS Density - lbs/gal: 7.95-13.0 Solids, wt. %: 51-70 Solids, volume: 42.9-60 Viscosity: 35-42 Sec. Flash Point ° F. 80 Application Method: Conventional of HVLP Reduction for Application: 5-base; 1-XL009; 1-acetone 6-base; 1-XL003; 1-20LT161 Pot Life: 3-HRS @ 70° F. Cure Schedule: 30 min @ 180° F. Gloss 60°: Flat to 96 VOC as supplied - lbs/gallon: 3.0-3.6 VOC as applied - lbs/gallon: 2.9-3.5 - The 121 Series is a medium solids, low temperature cure two component polyurethane for use on metal and plastic. It is used for industrial and automotive applications. This system has excellent chemical, stain, and water soak resistance. It has good adhesion to many substrates with good mar and abrasion resistance and it has 2 H hardness.
-
CHARACTERISTICS Density - lbs/gal: 7.92-11.0 Solids, wt. %: 45-67 Solids, volume: 37-48 Viscosity: 45 sec Zahn#2 Flash Point ° F. 78 Application Method: HVLP; Conv. Reduction for Application: 4-base; 1-XL009 5-base; 1-XL003 Pot Life: 2 hrs @ 70° F. Cure Schedule: 35 min @ 160° F., Air Dry tack free 40 min Gloss 60°: Flat to 96 VOC as supplied - lbs/gallon: 3.6-4.3 VOC as applied - lbs/gallon: 3.37-4.0
Both polymer adhesion paints of Examples 1 and 2 are manufactured and distributed by: - www.primecoatings.net
- The polymer adhesion paints may be applied in any manner known in the art including, but not limited to, spraying, dipping, brushing, sponging and any other paint application method. In various embodiments polymer adhesion paint is applied by spraying. Generally, less than 40 mils of paint are applied to the surface intended to be painted. In other embodiments less than 20 mils of paint is applied and in other embodiments less than 10 mils of paint is applied to the surface intended to be painted. In one example, approximately 0.2 to 1.5 mils dry film thickness of base color was applied to the entire surface of a fascia. Once the base paint has been applied, secondary colors may optionally be applied to the wet or dry base coat as desired. Such secondary colors may be applied in similar ways as the base paint, such as spraying, dipping, brushing, sponging and any other spray technique known in the art. It is also noted that a primer layer may be applied to the substrate surface prior to applying the paints described herein. For example, a coating of binel, parylene or another primer coat may be applied to the surface prior to applying the paint to promote optimum adhesion.
- Once the paint has been applied to the desired surface of the mass confinement cells, the product is then cured. In various embodiments of the present invention, the product is oven cured following painting at a temperature of 220° F. and less (e.g. 175° F. to 220° F.); in other embodiments 185° F. and less (e.g. 150° F. to 185° F.); and in still other embodiments 160° F. and less (e.g. 100° F. to 150° F.). In various embodiments the paint, is cured at the above mentioned temperatures for a period of 2 minutes to 4 hours; in other embodiments 5 minutes to 2 hours and in still
other embodiments 10 minutes to 30 minutes. The product is then allowed to air dry. Once air dried, the mass confinement cell is ready for installation. It is noted that the curing process may be performed at room temperatures, but the curing time usually will be lengthened accordingly. - As previously indicated the
mass confinement cells 10 of the present invention generally include aframe more side panels front panel back panel side panels front panel front panel side panel front panel front panel front panels front panels side panels front panel back panel chamber side panels - In various embodiments of the present invention, the
mass confinement cell front panel fascia confinement cell mass confinement cells front panel fascia confinement cell front panel fascia back panel confinement cell front panel fascia front panel fascia confinement cell mass confinement cell confinement cell adjacent cells FIG. 32 depicts one embodiment of afront panel top panel 64. - The partial
top panel 64 may further include optional top side panels 66 that extend downward from the partialtop panel 64 and may extend over or within the side panels (not shown) of the confinement cell (not shown). The partialtop panel 64 may also include one or more planting apertures (not shown) that allow for the growth of plants from the top of themass confinement cells - Also, various embodiments, as depicted in may also include a
front panel member mechanisms front panel member FIG. 32 depicts afront panel 24 that includes more than two securingmechanisms 22. This is advantageous if partial cells are required. For example, theconfinement cell side panel mechanism front panel member confinement cell additional securing mechanisms front panel member outer securing mechanisms side panel cut front panel Partial confinement cells confinement cell - It is noted that in some embodiments, the partial
top panel 64, as depicted inFIG. 32 , may extend back from the top edge of thefront panel partition 44. Therefore, an example of such an embodiment would provide for a partialtop panel 64 extending from thefront panel 24 to thepartition 44 on the mass confinement cell ofFIG. 13 . In some embodiments, ribbing or inner stability ridges (not shown) may be positioned between thefront panel 24 andpartition 44 to provide additional stability to the structure. -
FIGS. 33 and 34 depict various embodiments of top covers 76 and bottom covers 78, which are configured and adapted to securely fit over or under embodiments of themass confinement cell such covers top cover 76 generally includes a continuoustop panel 80 that includes optional overlappingedges 82, which overlap securely over the outside side andback panels edges 82 may be present around the entire perimeter of thetop panel 80. Alternately, a forward extendingapron 84 may be positioned at the front of thetop cover 76 and utilized to secure thecover 76 to theadjacent confinement cell apron 84 under the top panel of thecell - Embodiments of the bottom covers 78 of the present invention, as depicted in
FIG. 34 , may include abottom panel 86 with attachedbottom side walls 88 extending around the perimeter of thebottom panel 86. Theside walls 88 may be configured to overlap the front, back andside panels side panels FIG. 34 , the overlapping sides may include anoptional channel 90 for receiving and retaining the front, side andback panels adjacent confinement cell 10 above. Alternatively, the top covers 76 and/or bottom covers 78 may include only atop panel 80 orbottom panel 86 that nest and optionally secure into place just within thefront panel 24, backpanel 14 andside panels 14 of theconfinement cell 10. Additionally, thetop cover 76 may include one or more planting apertures (not shown) for allowing the growth of vegetation from the mass confinement cell. -
FIGS. 35-38 depict other embodiments of the present invention wherein themass confinement cells device 98. It is noted that in themass confinement cell device 98 may be a securing mechanism as described above or a variation thereof. In various embodiments, as depicted inFIG. 35 the interconnectingdevice 98 includes a peg and socket system having one or moreinsertable pegs 92 to adjoin two or more confinement cells by inserting thepegs 94 intothreads 94 that form a socket. The sockets are generally positioned on an edge or just inside the edge of the front, side and/orback panels back panels panels pegs 92 are configured to be securely receivable in the sockets and may be configured to swivel theconfinement cell - Alternatively, in one embodiment of the present invention side by side
adjacent confinement cells clipping device 108. In one embodiment as depicted inFIG. 36 , theclipping device 108 may be configured in a U shape and sized to snuggly fit over theside panels 16 of two adjacent confinement cells. -
FIG. 37 depicts an additional embodiment of the present invention, similar to hook attachments, wherein themass confinement cell confinement cell hook 110 fromadjacent confinement cells side panel mass confinement cell opposite side panel adjacent cell - Another advantage of certain embodiments of the mass confinement cells of the present invention is that they also allow for easy storage and transport due to the stackable capabilities present. For example, mass confinement cell are easily transported and stored by positioning the
front panel back panels side panels - As previously suggested, the
mass confinement cell such cells FIG. 39 , embodiments of themass confinement cell structural grid 112 that is attached to aconfinement cell front panel 12, backpanel 14, bottom panel). The grid is generally buried behind the wall constructed of the confinement cells of the present invention and acts to support and stabilize the wall from moving forward away from the embankment it is protecting and also stabilizes the soil or fill material positioned behind the wall. - In various embodiments of the present invention, a plurality of
confinement cells cells confinement cells - As previously mentioned, in various embodiments of the present invention, at least the front panel or fascia of the mass confinement cells include a deterioration resistant, substantially rigid composite or polymeric material including, but not limited to, plastic (e.g. recycled or virgin), a rubber composition, fiberglass, or any other similar material or a combination thereof. However, in many embodiments of the present invention, all of the components of the mass confinement cell comprise a deterioration resistant, substantially rigid composite or polymeric material. In various embodiments of the present invention materials comprise light-weight and slightly flexible polymers, such as high and low density polyethylene. However, other plastics may also be used. Examples of other plastics include, but are not limited to polypropylene, acrylonitrile-butadiene-styrene (ABS), Polyethylene terephthalate (PET), polycarbonate, poly(butylene terephthalate) (PBT), poly(cyclohexanedimethylene terephthalate) (PCT), styrene-acrylonitrile copolymers (SAN), polyesters, polystyrene, polyvinyl chloride (PVC), polyurethane, copolymers including one or more of the previously mentioned polymers and combinations thereof. It is also noted that the deterioration polymeric materials may also be utilized with filler materials or recycled filler materials, such as titanium, carbon fibers, nylon, talc, glass, saw dust or paper byproducts, plastic and the like. Generally, the embodiments of the present invention may comprise any type of material that would have the similar characteristics to plastic, vinyl, silicone, fiberglass, rubber or a combination of these materials. However, in some embodiments one or more components, such as the frame may be manufactured from rigid materials such as metals and alloys (e.g. steel, aluminum), wood, ceramics and the like. It is noted that the material utilized in the present invention should be rigid enough to hold its form upon addition of filling material and also when placed in contact with other objects. Also the panels of the mass confinement cells should be substantially non-collapsible when in a filled and stacked state. Another material that may be utilized to form the components of the present invention may comprise a material similar to that utilized in the production of some types of garbage cans or the utilization of recycled rubber from objects such as tires. Such materials would be capable of holding rigidity and still offer flexibility when placed in contact with other objects, such as ice. Also, such materials have the ability to regain its original form when the object or material has been removed.
- Embodiments of the present invention may also vary in appearance. Since embodiments of the present invention may be manufactured by a process such as injection molding, structural foam molding, extrusion, thermo-forming, compression molding, roto-molding and the like, the molds may include any type of design or shape. Furthermore, the mass confinement cells may be manufactured in a multitude of different sizes, shapes and configurations. For example, an embankment or steep shoreline could support a retaining wall configured in a step like arrangement or design. Such a structure may be utilized as a retaining wall and/or a stairway down to a beach or to the water. In another embodiment, multiple
mass confinement cells - Additionally, in various embodiments of the present invention, one or more lighting devices may be incorporated into the mass confinement cells of the present invention. For example, lighting devices (e.g. Light Emitting Diodes (LEDs), halogen lights, fluorescent lights, incandescent lights) may be attached to the frame, pass through the frame or attached to the front or back surface of the fascia. Such lighting devices, when lit, will illuminate the front panel of the frame and/or the fascia. Any power source may be utilized to power the lighting devices. Examples of power sources that may be utilized with the mass confinement cells of the present invention include, but are not limited to, batteries, conventional electrical circuits and wiring, solar, wind or any other source that would provide the requisite power to light the lighting device. In some embodiments, solar panel lighting fixtures are affixed or pass through the front panel of the frame, thereby positioning such lighting fixtures between the frame and fascia. In other embodiments one or more lighting devices may be position on the perimeter of the front panel and fascia to thereby illuminate the front surface of the mass confinement cell.
- As previously suggested the environment resistant mass confinement cell is utilized in the construction of any type of wall or border. In application, the
confinement cells confinement cells load cell 204 andfascia 354 to aframe 212 or attaching the enclosingmember frame mass confinement cell confinement cells confinement cells individual confinement cell confinement cells chamber mass confinement cell mass confinement cell mass confinement cell chamber cell mass confinement cells - Generally, a continuous chamber system retaining wall includes stacked rows wherein
individual confinement cells mass confinement cells mass confinement cells cells other cells mass confinement cells mass confinement cells - Each
mass confinement cell - Furthermore, in various embodiments, the
mass confinement cells confinement cells peg extensions 52 are included on theconfinement cell individual confinement cell devices 108 or hooks 110 are present with theconfinement cell - As previously mentioned, upon completion of the top row of the retaining wall, a cover, aesthetic top border or
cell cap 114 may be placed on or over the top row to close and seal the continuous chamber system or to provide an aesthetic finishing border to the top of the retaining wall or earth retention system. One embodiment of acell cap 114, as depicted inFIG. 40 , may be polygonal in shape and include textured and designed faces on both thefront panels 24,back panels 14 and top of thecell cap 114. The cell caps 114 may further include setting pegs (not shown), similar to those depicted in the previous confinement cell embodiments, that may be utilized to secure thecell cap 114 to themass confinement cells mass confinement cells thinner cap 114 that includes a plurality of reinforcing partitions orribs 116. -
FIG. 41 depicts an exploded view of another embodiment of acell cap 114 that may be utilized with the mass confinement cell systems of the present invention. Thecell cap 114 of the this embodiment is intended to wholly or partially cover theconfinement cells cell cap 114 of this embodiment may extend a distance from the front edge, or slightly overhanging the front edge of themass confinement cell confinement cells cell cap 114 may extend back a distance of approximately between 5% to 110% of theconfinement cell - The
cell cap 114 of the embodiment depicted inFIG. 41A generally includes atop cap 118 that is engageable with aconfinement cell cover 120 as depicted inFIG. 41B . Thecell cover 120 generally engages theconfinement cell cell cap 114 into position on the wall or revetment. Thecell cover 120 can engage themass confinement cell more cover fasteners 122 that may engage the confinement cell at any applicable surface (e.g. the front panel, side panels, partitions). Thecover fasteners 122 may be any type of fastening device, such as pegs, rivets, screws, adhesives, hooks, snaps, tabs and any other means that will secure thecell cap 114 to thecell confinement cells top cap 118 of this embodiment engages thecell cover 120 by any means to adequately secure thetop cap 118 to thecell cover 120. For example, snaps, pegs, tabs, adhesives and any other means to fasten and secure the top cap may be utilized. Additionally, thetop cap 118 may further include one ormore ribs 28 to provide additional structural support to thetop cap 118. Thecell cap 114 may further include one or more cellcap end caps 124 that may be secured to the ends of thecell cap 114 to close the outer edges. SeeFIGS. 41C-D for a back and front view of the end cap 146. -
FIG. 42 depicts another embodiment of acell cap 114 that may be utilized with themass confinement cells cell cap 114 of this embodiment generally includes atop cap 118 adjoined to acell cover 120. Thetop cap 118 may be integrally adjoined to thecell cover 120 or may be a separate component attachable to thecell cover 120. Thetop cap 118 may further include a plurality ofribs 28 to provide additional stability and structure. Similar to the previous embodiment, thecell cover 120 can engage themass confinement cell more cover fasteners 122 that may engage the confinement cell at any applicable surface (e.g. the front panel, side panels, partitions). Thecover fasteners 122 may be any type of fastening device, such as pegs, rivets, screws, adhesives, hooks, snaps, tabs and any other means that will secure thecell cap 114 to thecell confinement cells flap 123. In various embodiments, the extension flaps may be placed on a track that allows for the extension or retraction of theflaps 123. -
FIG. 43 depicts yet another embodiment of acell cap 114 that may be utilized with themass confinement cells cell cap 114 of this embodiment generally includes atop cap 118 adjoined to acell cover 120 and one or more anchoring devices. The anchoring devices in this embodiment may include one or more arms 126 that are operably adjoined to one ormore setting extensions 52. The settingextensions 52 may further be locking setting extensions that are configured to secure under an anchoring ridge or slot positioned in the back panel or load cell of the mass confinement cells positioned below. Additionally, the arms 126 may be integrally adjoined to thetop cap 118 or adjoined with living hinges 56 and securing snaps, which would allow for thecell cap 114 to be transported and/or stored in a flat or nested configuration. Similar to the previous embodiments, thecell cover 120 can engage themass confinement cell more cover fasteners 122 that may engage the confinement cell at any applicable surface (e.g. the front panel, side panels, partitions). Thecover fasteners 122 may be any type of fastening device, such as pegs, rivets, screws, adhesives, hooks, snaps, tabs and any other means that will secure thecell cap 114 to thecell confinement cells - The
top cap 118 of many embodiments will include the texture and color of all the surfaces intended to be exposed on thefront panel fascia cell confinement systems top cap 118 may further include a plurality ofribs 28 to stabilize thetop cap 118 and prevent crushing or damaging. Thetop cap 118 andtop cover 120 in a number of embodiments may be polygonal in shape, thereby allowing for acontinuous cell cap 114 alignment over the length of a wall or revetment. The polygonal shape also allows for a continuous coverage when curving a wall structure. - Embodiments of the present invention may also be used in conjunction with regular dry cement process blocks, bricks or stones, such as those produced by Keystone®, Anchor® Wall Systems or Allan Block®. A retaining wall constructed in water or along a waterfront property may utilize the mass confinement cells of the present invention at water level and below and then the conventional retaining wall materials can be used on top of the mass confinement cells of the present invention. The utilization of the mass confinement cells of the present invention would allow ease in matching colors with the conventional retaining wall building materials because the materials utilized to manufacture the present invention can be colored and designed to match virtually any type of retaining wall construction material.
- Finally, the various molding and fabrication processes may be utilized with other landscaping products. For example, the solid surface coating, a polymeric sheet or polymer adhesion paint may be administered or laminated to any landscaping product comprised of a deterioration resistant material (e.g. plastic, fiberglass, etc.), such as landscaping edgers, stepping or patio stones, artificial rocks and boulders, mass confinement cell front panels and fascia and lawn furniture. In such embodiments, the solid surface coating, polymeric sheet or polymer adhesion paint is applied to one or more surfaces of the landscaping products.
FIGS. 44 a-b and 45 a-b depict two embodiments of the landscaping products that may provide surfaces coated with the solid surface coating, polymeric sheet or thermal paint of the present invention.FIGS. 44 a and 44 b depict a top view and bottom view of an edger andFIGS. 45 a and 45 b depict a top view and bottom view of a stepping stone. In both of these embodiments, the surface exposed to the outside environment is coated with the solid surface coating or polymeric sheet. - While the invention has been illustrated and described in detail in the drawings and foregoing description, such an illustration and description is to be considered as exemplary and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.
Claims (20)
1. A mass confinement cell comprising:
a frame including a panel operably adjoined to two or more side panels, the side panels extending back from a front panel of the cell at an angle of less than 90°,
a front surface adjoined to or formed into the front panel or a fascia and having a molded and/or fabricated natural appearance that is produced by imaging an actual natural surface and applying one or more laminates, surface coatings or paints to the front surface;
an enclosing member that is operably adjoined to the frame to form a chamber;
one or more anchoring devices selected from a group consisting of a retaining flange, peg extensions, lockable peg extensions and securing pins; and
an open top surface including no top panel or a partial top panel.
2. The mass confinement cell of claim 1 , wherein the mass confinement cell includes one or more securing mechanisms to secure one or more of the side panels to the panel and/or the enclosing member.
3. The mass confinement cell of claim 1 wherein the frame, front surface and enclosing member comprise one or more deterioration resistant composite or polymeric materials.
4. The mass confinement cell of claim 3 wherein the deterioration resistant composite or polymeric materials selected from the group consisting of polyethylene, polypropylene, polyurethane, Acrylonitrile-butadiene-styrene (ABS), Polyethylene terephthalate (PET), polycarbonate, Poly(butylene terephthalate) (PBT), Polyethylene terephthalate (PET), polycarbonate, Poly(cyclohexanedimethylene terephthalate) (PCT), polyester, styrene-acrylonitrile copolymers (SAN), polystyrene, and combinations thereof.
5. The mass confinement cell of claim 3 , wherein the composite or polymeric material includes one or more colors, filler materials, and/or additives.
6. The mass confinement cell of claim 1 , wherein the cell includes one or more partitions.
7. The mass confinement cell of claim 1 , wherein the enclosing member includes one or more load cells.
8. The mass confinement cell of claim 1 , wherein the enclosing member includes one or more enclosing bars.
9. The mass confinement cell of claim 2 , wherein the one or more securing mechanisms are selected from the group consisting of peg and socket systems, living hinges, T-slot systems and snap and snap aperture systems.
10. The mass confinement cell of claim 1 , wherein the imaged actual natural surface is selected from the group consisting of stone, rock and wood.
11. A method of building a deterioration resistant retaining wall comprising;
a) placing a plurality of mass confinement cells in one or more stacked rows, the mass confinement cells comprising:
i) a frame including a panel and two side panels operably adjoined to the panel;
ii) a front surface adjoined to or formed into the front panel or a fascia and having a molded and/or fabricated natural appearance that is produced by imaging an actual natural surface and applying one or more laminates, surface coatings or paints to the front surface;
iii) an enclosing member that is operably adjoined to the frame to form a chamber;
iv) one or more anchoring devices for securing each cell to adjacent cells or securing them into position in the retaining wall; and
v) an open top surface including no top panel or a partial top panel;
b) filling the chamber of each confinement cell in the row(s) with one or more fill materials;
c) positioning a second set of one or more rows of mass confinement cells above the first row(s) of mass confinement cells;
d) filling the second set of row(s) of mass confinement cells with a fill material; and
e) continuing the previously described steps until the desired number of rows is achieved.
12. The method of building a deterioration resistant retaining wall of claim 11 , wherein the cells of adjacent rows are staggered.
13. The method of building a deterioration resistant retaining wall of claim 11 , wherein the mass confinement cells include one or more securing mechanisms to secure one or more of the side panels to the panel and/or the enclosing member.
14. The method of building a deterioration resistant retaining wall of claim 11 , wherein the frame, enclosing member, a fascia or a combination thereof include one or more deterioration resistant composite or polymeric materials.
15. The method of building a deterioration resistant retaining wall of claim 14 , wherein the one or more deterioration resistant composite or polymeric materials selected from the group consisting of polyethylene, polypropylene, polyurethane, Acrylonitrile-butadiene-styrene (ABS), Polyethylene terephthalate (PET), polycarbonate, Poly(butylene terephthalate) (PBT), Polyethylene terephthalate (PET), polycarbonate, Poly(cyclohexanedimethylene terephthalate) (PCT), polyester, styrene-acrylonitrile copolymers (SAN), polystyrene, and combinations thereof.
16. The method of building a deterioration resistant retaining wall of claim 14 , wherein the one or more composite or polymeric materials includes one or more colors, filler materials, and/or additives.
17. The method of building a deterioration resistant retaining wall of claim 11 , wherein the molded or fabricated front surface is positioned on a fascia.
18. The method of building a deterioration resistant retaining wall of claim 11 , wherein the anchoring devices selected from a group consisting of a retaining flange, peg extensions and securing pins.
19. The method of building a deterioration resistant retaining wall of claim 11 , wherein the enclosing member includes one or more load cells.
20. The method of building a deterioration resistant retaining wall of claim 11 , wherein the enclosing member includes one or more enclosing bars.
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Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/463,816 Expired - Fee Related US7866923B2 (en) | 2005-08-10 | 2006-08-10 | Continuous chamber mass confinement cells and methods of use thereof |
US12/987,835 Abandoned US20110150579A1 (en) | 2005-08-10 | 2011-01-10 | Continuous chamber mass confinement cells and methods of use thereof |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US11/463,816 Expired - Fee Related US7866923B2 (en) | 2005-08-10 | 2006-08-10 | Continuous chamber mass confinement cells and methods of use thereof |
Country Status (5)
Country | Link |
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US (2) | US7866923B2 (en) |
EP (1) | EP1913205A1 (en) |
AU (1) | AU2006279890A1 (en) |
CA (1) | CA2618391A1 (en) |
WO (1) | WO2007021880A1 (en) |
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US20130315679A1 (en) * | 2012-05-22 | 2013-11-28 | Westblock Systems, Inc. | Retaining wall system |
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Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
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US20100284751A1 (en) * | 2009-05-05 | 2010-11-11 | Price Brian A | Wall Block With Barrier Member |
US8430603B2 (en) | 2009-05-05 | 2013-04-30 | Mortarless Technologies, Llc | Wall block with barrier member |
US20130315679A1 (en) * | 2012-05-22 | 2013-11-28 | Westblock Systems, Inc. | Retaining wall system |
US9428878B2 (en) * | 2012-05-22 | 2016-08-30 | Westblock Systems, Inc. | Retaining wall system |
US9562338B2 (en) | 2012-05-22 | 2017-02-07 | Westblock Systems, Inc. | Retaining wall system |
US9902600B2 (en) | 2012-05-22 | 2018-02-27 | Westblock Systems, Inc. | Retaining wall system |
Also Published As
Publication number | Publication date |
---|---|
AU2006279890A1 (en) | 2007-02-22 |
US7866923B2 (en) | 2011-01-11 |
US20070036616A1 (en) | 2007-02-15 |
WO2007021880A1 (en) | 2007-02-22 |
EP1913205A1 (en) | 2008-04-23 |
CA2618391A1 (en) | 2007-02-22 |
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Legal Events
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STCB | Information on status: application discontinuation |
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