U.S. patent application number 12/971672 was filed with the patent office on 2011-07-28 for landscaping products including continuous chamber mass confinement cells and methods of use therof.
This patent application is currently assigned to NEW TECHNOLOGY RESOURCES, INC.. Invention is credited to Daniel Darst, John F. Dolan, Edward Alan Knudson, Eric Jason Krause, Vishal N. Lokhande, Lee Gordon Macklem, Robert J. Race.
Application Number | 20110182674 12/971672 |
Document ID | / |
Family ID | 46325879 |
Filed Date | 2011-07-28 |
United States Patent
Application |
20110182674 |
Kind Code |
A1 |
Knudson; Edward Alan ; et
al. |
July 28, 2011 |
LANDSCAPING PRODUCTS INCLUDING CONTINUOUS CHAMBER MASS CONFINEMENT
CELLS AND METHODS OF USE THEROF
Abstract
The present invention relates to environment resistant
landscaping products, such as retaining wall and earth retention
products, edgers, paving stones and the like, that provide a
natural earthen appearance, such as rock, stone, sand, soil, clay,
wood, trees and foliage, water, or any other natural earthen
appearance. The present invention also includes a mass confinement
cell that may be used in retaining walls and earth retention
systems that has a natural earthen appearance 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.
Inventors: |
Knudson; Edward Alan;
(Annandale, MN) ; Dolan; John F.; (Golden Valley,
MN) ; Race; Robert J.; (Eagan, MN) ; Lokhande;
Vishal N.; (Minneapolis, MN) ; Darst; Daniel;
(Zimmerman, MN) ; Macklem; Lee Gordon; (New Hope,
MN) ; Krause; Eric Jason; (Big Lake, MN) |
Assignee: |
NEW TECHNOLOGY RESOURCES,
INC.
Edina
MN
|
Family ID: |
46325879 |
Appl. No.: |
12/971672 |
Filed: |
December 17, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11463820 |
Aug 10, 2006 |
7854573 |
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12971672 |
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11126546 |
May 11, 2005 |
7198435 |
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11463820 |
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60569886 |
May 11, 2004 |
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60777617 |
Feb 28, 2006 |
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60741737 |
Dec 2, 2005 |
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60707032 |
Aug 10, 2005 |
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Current U.S.
Class: |
405/284 |
Current CPC
Class: |
E02D 29/025 20130101;
E02D 29/02 20130101 |
Class at
Publication: |
405/284 |
International
Class: |
E02D 5/00 20060101
E02D005/00 |
Claims
1. A mass confinement cell comprising: a front panel including one
or more deterioration resistant composite or polymeric materials
and having a molded and/or fabricated front surface produced from a
mold that has a surface formed from imaging an actual natural
surface; the front surface is adjoined to or formed on the front
panel to provide texture and color that mimics the actual natural
surface; a back panel including one or more deterioration resistant
composite or polymeric materials; one or more side panels including
one or more deterioration resistant composite or polymeric
materials that are operably adjoined to one or both of the front
panel and back panel to form a chamber; and one or more locking peg
extensions and one or more ridges or slots for accepting locking
peg extensions from one or more adjacent cells.
2. The mass confinement cell of claim 1, wherein the mass
confinement cell has no bottom panel or a partial bottom panel and
further includes an open top surface including no top panel or a
partial top panel extending from a front edge of the front panel
back a length no more than 75% of the width of the cell.
3. The mass confinement cell of claim 1 further including one or
more securing mechanisms, wherein the one or more securing
mechanisms include integral peg and socket systems.
4. The mass confinement cell of claim 1 wherein the composite or
polymeric materials are selected from the group consisting of
polyethylene, polypropylene, polyurethane,
Acrylonitrile-butadiene-styrene (ABS), Polyethylene terephthalate
(PET), polycarbonate, Poly(butylene terephthalate) (PBT),
Poly(cyclohexanedimethylene terephthalate) (PCT),
styrene-acrylonitrile copolymers (SAN), polystyrene and
combinations thereof.
5. The mass confinement cell of claim 4, wherein the composite or
polymeric material includes one or more filler materials, colors
and/or additives.
6. The mass confinement cell of claim 1 wherein the molded or
fabricated front surface is molded or fabricated in the front
panel.
7. The mass confinement cell of claim 1 wherein the front panel
includes a fascia having a molded or fabricated front surface.
8. The mass confinement cell of claim 1, wherein the back panel and
side panels are integrally adjoined.
9. The mass confinement cell of claim 1, wherein the front panel
and side panels are integrally adjoined.
10. The mass confinement cell of claim 4, wherein the imaging is
performed by casting or digitally scanning the actual natural
surface.
11. The mass confinement cell of claim 1, wherein the actual
natural surface is formed from a mold having the image of cut
stone, brick or wood.
12. The mass confinement cell of claim 1, further including a load
cell positioned within the front panel and side panels.
13. A method of building a deterioration resistant retaining wall
comprising: a) placing a plurality of the mass confinement cells
comprising a front panel including one or more deterioration
resistant composite or polymeric materials and having a molded
and/or fabricated front surface produced from a mold that has a
surface formed from imaging an actual natural surface; the front
surface is adjoined to or formed on the front panel to provide
texture and color that mimics the actual natural surface; a back
panel including one or more deterioration resistant composite or
polymeric materials; one or more side panels including one or more
deterioration resistant composite or polymeric materials that are
operably adjoined to one or both of the front panel and back panel
to form a chamber; and one or more locking peg extensions and one
or more ridges or slots configured to receive locking peg
extensions from one or more adjacent cells; b) filling the chamber
of each cell in the row with one or more fill materials; c)
positioning a second row of mass confinement cells above the first
row of mass confinement cells; d) filling the second row of mass
confinement cells with a fill material; and e) continuing the
previously described steps until the desired number of rows is
achieved.
14. The method of building a deterioration resistant retaining wall
of claim 13, wherein the mass confinement cell has no bottom panel
or a partial bottom panel and further includes an open top surface
including no top panel or a partial top panel extending from a
front edge of the front panel back a length no more than 75% of the
width of the cell.
15. The method of building a deterioration resistant retaining wall
of claim 13, wherein the composite or polymeric materials are
selected from the group consisting of polyethylene, polypropylene,
polyurethane, Acrylonitrile-butadiene-styrene (ABS), Polyethylene
terephthalate (PET), polycarbonate, Poly(butylene terephthalate)
(PBT), Poly(cyclohexanedimethylene terephthalate) (PCT),
styrene-acrylonitrile copolymers (SAN), polystyrene and
combinations thereof.
16. The method of building a deterioration resistant retaining wall
of claim 13, wherein the composite or polymeric material includes
one or more filler materials, colors and/or additives.
17. The method of building a deterioration resistant retaining wall
of claim 13, wherein the molded or fabricated front surface is
molded or fabricated in the front panel or the front panel includes
a fascia having a molded or fabricated front surface.
18. The method of building a deterioration resistant retaining wall
of claim 13, wherein the imaging is performed by casting or
digitally scanning the actual natural surface.
19. The method of building a deterioration resistant retaining wall
of claim 13, wherein the actual natural surface is formed from a
mold having the image of cut stone, brick or wood.
20. The method of building a deterioration resistant retaining wall
of claim 13, further including a load cell positioned within the
front panel and side panels.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser.
No. 11/463,820 filed on Aug. 8, 2006, which is a continuation in
part application of U.S. application Ser. No. 11/126,546 filed on
May 11, 2005, which claims priority to U.S. Provisional Application
Ser. No. 60/569,886 filed on May 11, 2004; U.S. application Ser.
No. 11/463,820 further 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, U.S.
Provisional Application No. 60/777,617 filed on Feb. 28, 2006, and
is related to U.S. application Ser. No. 11/463,816 filed on Aug.
10, 2006. The contents of the seven previously mentioned
applications are incorporated by reference herein.
FIELD OF THE INVENTION
[0002] The present invention relates to environment resistant
landscaping products, such as retaining wall and earth retention
products, edgers, paving stones and the like, that provide a
natural earthen appearance, such as rock, stone, sand, soil, clay,
wood, trees and foliage and water, or any desired design and/or
appearance. The present invention also includes a mass confinement
cell 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 that generally provides weight, stability and
security to a retaining wall constructed of such mass confinement
cells.
BACKGROUND OF THE INVENTION
[0003] 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 and/or rough terrain and
to simply beautify areas of a property.
[0004] 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).
[0005] 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.
[0006] 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.
[0007] 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.RTM. Inc. or Anchor.RTM. 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.
[0008] 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.
SUMMARY OF THE INVENTION
[0009] 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 front panel adjoined to a back panel by
one or more side panels to thereby form a continuous chamber. The
continuous chamber of the mass confinement cell allows the flow of
fill material to adjacent mass confinement cells below and above.
The deterioration resistant mass confinement cell is generally a
hollowed frame or shell of 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 retaining wall cells and also ultimately provides
stability and security to the retaining wall constructed of such
cells.
[0010] As previously mentioned, various embodiments of the
deterioration resistant mass confinement cells of the present
invention comprise a front panel, back panel and one or more side
panels, which adjoin the front panel and back panel thereby forming
a confinement cell having a continuous flow chamber. In various
embodiments at least two of the side panels extend from the front
panel to the back panel at angles (e.g. less than) 90.degree.,
thereby allowing for a back panel that is of shorter length than
the front panel. The shorter back panel allows the product to
produce curves in retaining walls or revetments. Additionally, 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.
[0011] 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 peg extensions or locking extensions for
interconnecting the stacked confinement cells. The peg extensions
or locking extensions assist in positioning and/or adjoining
adjacent cells and facilitating the flow of fill material to the
adjacent cells. Additionally, the peg extensions or locking
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.
[0012] In additional embodiments of the present invention, the
cells may comprise two or more separated panels that are adjoined
by a securing mechanism, such as a "T-hook and T-slot", or a "peg
and socket system". For example, the 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 that the various components nest and/or may be
transported in relatively flat panels.
[0013] 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.
[0014] 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.
[0015] 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.RTM.
or Anchor.RTM. 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.
[0016] 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.
[0017] 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 and/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.
[0018] 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.RTM. 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 the product, thereby making
it very beneficial for all applications that come in contact with
water.
[0019] 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 heavy, thereby making it difficult to install.
Furthermore, rip rap will generally 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.
[0020] 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.
[0021] 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1a is a front perspective view of one embodiment of a
deterioration resistant mass confinement cell.
[0023] FIG. 1b is a front perspective view of an embodiment of a
deterioration mass confinement cell with a beveled front panel.
[0024] FIG. 2a is a front perspective view of an embodiment of a
mass confinement cell having a T-slot securing mechanism.
[0025] FIG. 2b is a front perspective view of an embodiment of a
partial mass confinement cell having a peg and socket securing
mechanism and an inner partition.
[0026] FIG. 2c is a front perspective view of an embodiment of a
mass confinement cell having an integral peg and socket securing
mechanism.
[0027] FIG. 3 is a front perspective view of an embodiment of a
deterioration mass confinement cell including a peg and socket
securing mechanism and integral back and side panels.
[0028] FIG. 4 is a back perspective view of an embodiment of a
deterioration resistant mass confinement cell including a peg and
socket securing mechanism and integral back and side panels.
[0029] FIG. 5 is a front perspective view of an embodiment of a
front panel of a deterioration resistant mass confinement cell.
[0030] FIG. 6a is a perspective view of an embodiment of a
deterioration resistant mass confinement cell including a peg and
socket securing mechanism.
[0031] FIG. 6b is a perspective view of the Detail A peg and socket
securing mechanism of FIG. 9a.
[0032] FIG. 6c is a perspective view of the Detail B peg and socket
securing mechanism of FIG. 9a.
[0033] FIG. 7a is a back perspective view of one embodiment of a
stabilizing partition.
[0034] FIG. 7b is a front perspective view of one embodiment of a
stabilizing partition.
[0035] FIG. 8 is an exploded front view of one embodiment of a
deterioration resistant mass confinement cell including integral
side and back panels.
[0036] FIG. 9 is an exploded back view of one embodiment of a
deterioration resistant mass confinement cell including integral
side and back panels.
[0037] FIG. 10 is a front perspective view of one embodiment of a
deterioration resistant mass confinement cell including integral
side and back panels and a stabilizing partition.
[0038] FIG. 11a is a back perspective view of an embodiment of a
back panel that includes a locking peg extension.
[0039] FIG. 11b is a front perspective view of an embodiment of a
back panel that includes a locking peg extension.
[0040] FIG. 12 is a front perspective view of one embodiment of a
deterioration resistant mass confinement cell including an interior
partition.
[0041] FIG. 13 is an exploded front view of one embodiment of a
deterioration resistant mass confinement cell including an interior
partition.
[0042] FIG. 14 is a back perspective view of an embodiment of a
front panel of a deterioration resistant mass confinement cell of
FIG. 12.
[0043] FIG. 15 is a front perspective view of one embodiment of a
deterioration resistant mass confinement cell including two
adjoinable frame sections.
[0044] FIG. 16 is a back perspective view of one embodiment of a
deterioration resistant mass confinement cell including two
adjoinable frame sections.
[0045] FIG. 17 is an exploded front view of one embodiment of a
deterioration resistant mass confinement cell including two
adjoinable frame sections.
[0046] 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.
[0047] 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.
[0048] FIG. 19a is a front view of one embodiment of a fascia that
may be utilized with the deterioration resistant cells of the
present invention.
[0049] FIG. 19b is a back view of one embodiment of a fascia that
may be utilized with the deterioration resistant cells of the
present invention.
[0050] FIG. 20a is a front view of one embodiment of a fascia that
may be utilized with the deterioration resistant cells of the
present invention.
[0051] FIG. 20b is a back view of one embodiment of a fascia that
may be utilized with the deterioration resistant cells of the
present invention.
[0052] FIG. 21a is a front view of one embodiment of a fascia that
may be utilized with the deterioration resistant cells of the
present invention.
[0053] FIG. 22b is a back view of one embodiment of a fascia that
may be utilized with the deterioration resistant cells of the
present invention.
[0054] FIG. 22a is a perspective top view of one embodiment of an
edger that may include the surface coating or lamination of the
present invention.
[0055] FIG. 22b is a perspective bottom view of one embodiment of
an edger that may include the surface coating or lamination of the
present invention.
[0056] FIG. 23a is a perspective top view of one embodiment of a
paving stone that may include the surface coating or lamination of
the present invention.
[0057] FIG. 23b is a perspective bottom view of one embodiment of a
paving stone that may include the surface coating or lamination of
the present invention.
[0058] FIG. 24 is a perspective view of one embodiment of a front
panel including a partial top panel.
[0059] FIG. 25 is a perspective view of one embodiment of a front
panel including a partial top panel having a planting aperture.
[0060] FIG. 26 is a perspective view of one embodiment of a front
panel including a partial top panel and a plurality of securing
mechanisms.
[0061] FIG. 27 is a back perspective view of an embodiment of a
load cell that may be used with a deterioration resistant mass
confinement cell of the present invention.
[0062] FIG. 28a is a front view of one embodiment of an end cap
that may be utilized with the deterioration resistant cells of the
present invention.
[0063] FIG. 28b is a back view of one embodiment of an end cap that
may be utilized with the deterioration resistant cells of the
present invention.
[0064] FIG. 29 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.
[0065] FIGS. 30a-b are perspective views of two top cover
embodiments used to cap a deterioration resistant mass confinement
cell.
[0066] FIGS. 31a-b are perspective views of two bottom cover
embodiment used to seal a deterioration resistant mass confinement
cell.
[0067] FIG. 32 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.
[0068] FIG. 33 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.
[0069] FIG. 34 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.
[0070] FIG. 35 depicts a perspective view of a plurality of
deterioration resistant mass confinement cells in nesting
positions.
[0071] FIG. 36 depicts a perspective view of a plurality of
nestable deterioration resistant mass confinement cells without the
front panel in nesting positions.
[0072] FIG. 37 depicts a perspective view of an embodiment of a
deterioration resistant mass confinement cell including a
structural stabilization grid.
[0073] FIG. 38 depicts a perspective view of an embodiment of a
plurality of deterioration resistant mass confinement cells
adjoined to a cellular confinement system.
[0074] FIG. 39 depicts a perspective view of an embodiment of a
plurality of deterioration resistant mass confinement cells
adjoined to a cellular confinement system with a plurality of
reinforcing members.
[0075] FIG. 40a-b depict front perspective views of two retaining
walls constructed with embodiments of the mass confinement cells of
the present invention.
[0076] FIG. 41 depicts a front perspective view of one embodiment
of a cell cap that may be utilized with various embodiments of the
present invention.
[0077] FIG. 42 depicts an exploded view of one embodiment of a cell
cap that may be utilized with various embodiments of the present
invention.
[0078] FIG. 43a is a perspective view of one top cap embodiment of
the cell cap of FIG. 42.
[0079] FIG. 43b is a perspective view of one top cover embodiment
of the cell cap of FIG. 42.
[0080] FIG. 43c is a back perspective view of an end cap embodiment
of the cell cap of FIG. 42.
[0081] FIG. 43d is a front perspective view of an end cap
embodiment of the cell cap of FIG. 42.
[0082] FIG. 44 depicts a perspective view of one embodiment of a
cell cap that may be utilized with various embodiments of the
present invention.
[0083] FIG. 45 depicts a perspective view of one embodiment of a
cell cap including locking peg extensions that may be utilized with
various embodiments of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0084] 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.
[0085] Various embodiments of the deterioration resistant mass
confinement cell 10 generally comprise a front panel 12, a back
panel 14 and one or more side panels 16 as depicted in FIGS. 1a and
1b. The side panels 16 of these embodiment operably join the front
panel 12 and back panel 14 to form the confinement cell 10 having a
continuous flow chamber 18. The continuous flow chamber 18 is
positioned within the front panel 12, back panel 14 and side panels
16.
[0086] 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 of such confinement
cells, which include an open top and bottom, allows for the flow
and/or commingling of fill material from adjacent cells positioned
above and/or below through each cell's continuous flow chamber 18.
In other 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 commingling of fill material from one
confinement cell to cells positioned above and/or below.
[0087] Additionally, the mass confinement cell 10 of various
embodiments of the present invention may include two or more
separated panels 12, 14, 16 or sections that are operably connected
with one or more securing mechanisms 22 to join the two or more
panels 12, 14, 16 or two or more sections (e.g. sections may be two
or more panels that are integrally adjoined without securing
mechanisms), thereby forming the confinement cell 10. FIGS. 2a-c
depict three embodiments of the present invention that include
panels 12, 14, 16 that are adjoined with securing mechanisms 22. In
other embodiments, the mass confinement cells 10 utilize securing
mechanisms 22 to join three or more panels 12, 14, 16 or sections
to form the mass confinement cell 10. Also, in still other
embodiments, the mass confinement cells 10 of the present invention
utilize securing mechanisms 22 to join four or more separated
panels 12, 14, 16 or sections to form the confinement cell 10. In
many of these embodiments, the one or more side panels 16 are
operably joined to the front panel 12 and/or back panel 14 with two
or more securing mechanisms 22 to form a continuous flow chamber 18
within the mass confinement cell 10.
[0088] It will be found that various mass confinement cell
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). Such large
confinement cells allow for easy storage and transportation of such
mega-cells by allowing them to flatten or nest, thereby decreasing
the space needed for large numbers of cells.
[0089] In various embodiments of the present invention, the front
panel 12 of the cell may be flat, rounded or beveled and are
generally molded or fabricated (e.g. lamination, painting, U.V.
Coating) to provide the desired earthen appearance. FIG. 1a depicts
an embodiment of a cell 10 with a flat front panel 12. FIG. 1b
depicts an embodiment of a cell 10 with a beveled front panel 12.
FIG. 2a depicts an embodiment of a cell 10 with a rounded front
panel 12. However, it is noted that in other embodiments a fascia
may be secured to the front panel 12 to provide the desired
appearance. In various embodiments of the present invention, the
front panel or fascia may also be beveled, rounded, substantially
flat or include positions of relief to provide a more natural
earthen appearance, such as stone or wood.
[0090] FIGS. 3 and 4 depict another embodiment of the mass
confinement cell 10 of the present invention wherein the cell 10
includes side panels 16 and a back panel 14 that are formed or
manufactured in a single part or section 24, thereby foregoing the
need for one or more of the securing mechanisms 22 to secure the
side panels 16 with the back panel 14. It is noted that a section
may be a combination of two or more panels, such as a back panel
secured to one or more side panels or a front panel secured to one
or more side panels. Such an embodiment has benefits in providing
for additional stability of the confinement cell structure and the
ability to manufacture the entire confinement cell 10 with a
limited number of parts (e.g. two part system; a side/back section
and a front panel or a side/front section and a back panel). Such
embodiments allow for the back and side panels 14, 16 to be formed
in a single part by processes that have manufacturing benefits,
such as injection molding, structural foam molding (e.g. low
pressure multi-nozzle structural foam), extrusion or thermoforming.
Once the single back/side or front/side section 24 is provided, it
may be adjoined to a molded and/or fabricated front panel 12 or a
back panel 16 by securing the pieces together with one or more
securing mechanisms 22.
[0091] In various embodiment of the present invention, the front
panel 12 of the cell 10 may be flat, rounded or beveled. For
example, FIG. 5 depicts a front panel 12 of the cell 10 depicted in
FIGS. 1 and 2. The front panel 12 of this embodiment includes a
rounded front panel 12, but may include a flat or a beveled front
having one or more bends and/or slants. It is noted that the front
panel 12 may also include positions of relief or creases and clefts
to provide a more natural appearance.
[0092] The front panel of this embodiment further includes a front
plate 26 and a back plate 28 that are separated by one or more ribs
30 to adjoin and provide support and stability to the front plate
26 and back plate 28. Alternatively, a corrugated or waved ribbing
system (not shown) may separate the front plate 26 and back plate
28 rather than straight ribs to provide a pressure absorption
means, thereby removing the pressure produced by the fill material
on the front panel 12. The front panel 12 of this embodiment
further includes at least part of one or more securing mechanisms
22. As will be explained further below, the front plate 26 and/or
front panel 12 generally will display an earthen appearance or
other aesthetic design that may be molded into the surface or
applied to the surface.
[0093] As previously mentioned, various embodiments of the mass
confinement cell 10 generally include one or more securing
mechanisms 22 that provide a sufficient means for securing the
separated panels 12, 14, 16 to each other. A sufficient means is
generally one wherein the securing mechanisms 22 will not release
when the force of the fill material is applied to the panels 12,
14, 16 of the mass confinement cell 10. FIGS. 6a-6c depict one
embodiment of a securing mechanism 22 that may be utilized to form
one embodiment of a mass confinement cell 10 of the present
invention. FIG. 6a depicts one embodiment of a mass confinement
cell 10, wherein the confinement cell 10 includes a front panel 12
and back panel 14 adjoined to two side panels 16 with securing
mechanisms 22. FIGS. 6b and 6c depict one embodiment of a securing
mechanism 22 utilized to adjoin the panels 12, 14, 16 of the
confinement cell 10 of the present invention. In this embodiment,
the securing mechanism 22 includes a peg and socket system
including a peg 32 having a base 34 and two or more elongated keys
36 extending upward from the base 34. In some embodiments, the keys
36 may include a beveled top that allows for the keys 36 to be
inserted into a socket 38 and lock the panels 12, 14, 16 into place
when completely inserted.
[0094] Other embodiments of securing mechanisms that may be
utilized in the present invention include the peg and socket
systems (threaded, integrated and non-integrated) (See FIGS. 2b-c),
T-hook and T-slot (See FIG. 2a), locking snaps 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, U.S. Provisional Application 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 which are incorporated by reference
herein.
[0095] The various mass confinement cell embodiments may further
include one or more interior partitions 40. The interior partitions
40 may also be utilized to add additional support to the
confinement cell 10 to prevent any possible crushing or expansion
of the cell 10. FIGS. 3 and 4 depict one confinement cell
embodiment wherein the interior partitions 40 are within the
interior of the cell 10 and are present to define separate chambers
that can accommodate filling of each individual chamber 18 with
appropriate fill material, such as sand, gravel, crushed rock, pea
rock, soil, cement, concrete or any other suitable material. The
interior partitions 40 may be secured to the front panel 12, back
panel 14 or to the two side panels 16 utilizing one or more
securing mechanisms (e.g. peg and socket systems, T-hook and T-slot
systems, panel slot systems, snap systems or any other securing
means). Alternatively, the interior partitions 40 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.
[0096] FIGS. 7a and 7b depict interior and exterior views of one
embodiment of an interior partition 40. The interior partition 40
of this embodiment generally includes a sheet 42 having panel
attachments 44 at each end that can butt against and accommodate
securing of the partition 40 to a panel 12, 14, 16. As previously
mentioned, any securing or adjoining means may be utilized to
adjoin the interior partition 40 to the front panel 12, back panel
14 or side panels 16. To further stabilize the interior partition
40, the partition 40 may also include one or more ribs 28 that
extend between the panel attachments 44 or extend from the top to
the bottom of the interior partition 40 in a vertical
direction.
[0097] Additionally, multiple chambers 18 and partitions 40 also
allow for the mass confinement cell 10 to be cut into various
shapes or into partial cells and still maintain a chamber 18 that
can receive and retain fill materials. The ability to cut the
retaining cells 10 and still retain the same features is
particularly useful in preparing ends and awkward segments of
retaining walls. In one embodiment, a confinement cell 10, as
depicted in FIGS. 3 and 4, may be cut to a desired width, and
adjoined with a partition 40 positioned on the front panel 12 and
back panel 14 to thereby secure the front panel 12 to the back
panel 14 of the cell 10 at approximately the points where they were
cut.
[0098] FIGS. 8 and 9 depict exploded views of the mass confinement
cell of FIGS. 3 and 4, thereby illustrating the assembly of this
embodiment of the present invention. In this embodiment, the front
panel 12 includes two sockets 38 that are adapted to accept two
pegs 32 that are adjoined to the two side panels 16. In some
embodiments, the pegs 32 may be polygonal in shape and the socket
38 circular in shape to thereby secure the front panel 12 to the
remainder of the cell 10 when the pegs 32 are inserted into the
sockets 38. Furthermore, one or more partitions 40 may be
positioned in the cell 10 to added additional stability to the
confinement cell 10 or to provide an outer panel when cutting.
[0099] The various embodiments of the present invention may also
include one or more pins 46 that may be inserted into apertures in
the securing mechanism 22 or slots (not shown) positioned anywhere
on the confinement cell to further secure the confinement cell 10
into position in a retaining wall and also may secure the
confinement cell 10 to geo grid that is positioned between rows of
cells 10 when constructing a wall. FIGS. 8 and 9 depict one
embodiment of the pins 46 that may be utilized with the cells of
the present invention.
[0100] The various mass confinement cell embodiments of the present
invention may further include one or more positioning flanges or
setting extensions 48 as depicted in FIG. 9. On a constructed wall,
each retaining flange or setting extensions 48 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 setting extensions 48 extend downward from the back of
the back panel 14 and rest against the back of the mass confinement
cell or cells 10 located below. In other embodiments, the flange or
setting extensions 48 may also extend downward from the front panel
12, side panels 16 or an interior partition 40. FIG. 10 depicts one
embodiment wherein the setting extensions 48 extend downward from
the partition 40. The retaining flange or setting extension 48 may
be a unitary piece extending downward or upward from the mass
confinement cell 10 or a series of fingers extending downward or
upward from the confinement cell 10. It is also noted that the
setting extensions 48 may further be utilized to anchor the
confinement cell into the fill material below, thereby inhibiting
movement of the cell upon filling.
[0101] FIGS. 11a and 11b depict another embodiment of an anchoring
device and securing mechanism that may be utilized with various
embodiments of the present invention. In this embodiment the one or
more anchoring devices are peg extensions 48 that may be utilized
to position and secure each cell 10 when assembling a wall and may
also function to reduce or prevent overturn of the cells upon
filling and compacting the fill material. In this embodiment, the
peg extensions 52 are positioned on the back panel 14 are designed
to fit in or under one or more peg extension slots or ridges (not
shown) positioned on the two cells 10 located below when
constructing a wall, revetment or other earth retention system.
[0102] The back panel 14 of the embodiment of FIGS. 11a and 11b may
also include ribs 30 that can be positioned on the front or back of
the back panel 14 to provide additional stability. In various
embodiment when the back panel 14 is separated from the side panels
16, the back panel 14 may include a securing mechanism 22 in the
form of larger snaps 50 that may be inserted into apertures 52
positioned on the side panels 16.
[0103] In yet another embodiment of the present invention, a
securing mechanism 22 may be provided as a hybrid of a slot system
and the peg and socket system. FIG. 12 depicts one embodiment of
the present invention wherein an interior partition 40 includes the
hybrid slot system and peg and socket system to secure the front
panel 12 to the side panels 16 and back panel 14. As depicted in
the exploded view of FIG. 13, the partition 40 includes two or more
partition slits 54 to accommodate the securing of the two side
panels 16 and back panel 14. The side panels 16 also include one or
more panel slits 56 that are inserted into the slits 54 on the
interior partition 40. One or more partition pegs 58 may be
positioned adjacent to the partition slits 54 on the interior
partition 40 and utilized to stabilize the partition 40 by
positioning the pegs 58 against side panel ridges 60 after assembly
of the side panels 16 and back panel 14 to the interior partition
40. The side panel ridges 60 prevent the partition 40 from rotating
when assembly is complete. The partition 40 further includes one or
more sockets 38 for receiving pegs 32 positioned on the front panel
12 (as depicted in FIG. 14) when securing the front panel 12 to the
rest of the confinement cell 10.
[0104] As depicted in FIGS. 10 and 12, the stabilizing partition 40
may be included in the mass confinement cell 10 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 depicted in FIG. 10, the partition 40 may include
peg extensions 48 that operate as a cell positioning and securing
means when constructing a retaining wall. The peg extensions 48 may
be placed anywhere on the partition 40 including the ends and/or
dispersed along the bottom edge of the partition 40. In
construction of a wall, the peg extensions 48 may butt up against
one or more partitions present in blocks positioned below, thereby
holding the confinement cell 10 in position and providing an
indication of proper positioning of the cell 10. It is noted that
the peg extensions 48 may be included on the front panel 12, back
panel 16 or side panels 16 rather than or in addition to the
partition 40 so as to butt up against the front panel 12, back
panel 14 or partitions 40 of the confinement cells positioned
below.
[0105] FIGS. 15 and 16 depict another embodiment of the continuous
chamber mass confinement cell of the present invention. The
confinement cell 10 of this embodiment generally includes a frame
comprising a top frame section 62 and a bottom frame section 64
that are adjoined with one or more section fasteners 66. The
confinement cell 10 of this embodiment further includes a fascia 68
adjoined to the front of the cell 10. The fascia 68, in many
embodiments of the present invention, is generally adjoined with
one or more fascia fasteners 70, including but not limited to
locking pegs, hooks, screws, rivets, adhesives, pins and the like.
Generally, the top frame section 62 and bottom frame section 64 are
sloped so as to allow each section and other top frame sections
and/or bottom frame sections to nest within each other when
disassembled to enhance transportation and storage efficiency.
Finally, the confinement cell 10 of this embodiment may further
include one or more retaining flanges or setting extension 48 for
positioning and retaining each cell in the wall.
[0106] FIG. 17 depicts an exploded view of the mass confinement
cell illustrated in FIGS. 15 and 16. In assembly, the top frame
section 62 and bottom frame section 64 are pushed together as shown
until the fasteners 66 are engaged. Once the top frame section 62
and bottom frame section 64 are adjoined, the fascia 68 is secured
by aligning the fascia 68 with the front of the two sections 62, 64
and engaging the fascia 68 to the sections 62, 64 with the fascia
fasteners 70.
[0107] Other 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. 18a-b depicts a front view
and back view of one embodiment of a fascia 68 that may be utilized
with any embodiment of the present invention. Generally, the fascia
68 includes a front surface 72, a partial top panel 20 and one or
more fascia fasteners 70. The fascia 68 may also optionally include
wrap around sides 74, that wrap around the side panels 16 and
bottom panel upon assembly. The front surface 72, top panel 20 and
wrap around sides 74 may be textured and include color and/or other
additives (e.g. U.V. inhibitor) to provide the earthen appearance,
a crystalline appearance or desired aesthetic design. Additionally,
the fascia 68 may be prepared utilizing any of the techniques
discussed below or those known in the art for forming the desired
appearance. FIGS. 19a-b depict the front view and back view of a
fascia 68 of the present invention, wherein the fascia 68 also
includes a partial bottom panel 76. In all of the embodiments of
the present invention that include a fascia 68, the fascia 68 may
be permanently fixed to the front panel 12 or may be removable so
as to be replaced when damaged or a change is desired. The fascia
68 may also include one or more indentations 78 for surrounding a
load bearing member (not shown) that is positioned on the front
panel 12 and functions to support the load of the cells positioned
above. These load bearing members 204 are configured to take
pressure off the fascia 254 when a wall is assembled, thereby
allowing for greater ease in removal and replacement when
desired.
[0108] Another embodiment of a fascia 68 of the present invention
is depicted in FIGS. 20a and 20b. These FIGS. depict a front and
back view of one embodiment of a fascia 68 that may be utilized
with the confinement cells of the FIGS. described herein. Further
explanation of fascia design and manufacture will be discussed
below. The fascia 68 in various embodiments of the present
invention may include a plurality of ribs 30 to add stability and
structure to the fascia 68. It is noted that the top panel 20 of
the fascia 68 may include one or more indentations 78 to
accommodate and alternate between load bearing members 204 upon
administering the fascia 68 to the front panel 12.
[0109] FIGS. 21a-b depict yet another embodiment of the fascia 68
that may be utilized with the confinement cells 10 of the present
invention. The fascia 68 generally includes a front surface 72,
partial top panel 20, partial bottom panel 76, stability ribs 30
and two or more fascia fasteners 70. In this embodiment the fascia
fasteners 70 include two or more fascia keys 80 that are designed
to flex enough to pass through and aperture in the front panel 12,
thereby securing the fascia 68.
[0110] As previously suggested, 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.
approximately 1 feet in height, 2 feet wide and 1.5 feet deep or 2
feet in height, 4 feet wide and 2 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; see FIG. 20) 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 be transported or stored in flat or
nested configurations. Such configurations reduces the space needed
for the transportation and storage of large numbers of cells.
[0111] In various embodiments of the mass confinement cells 10 of
the present invention, the surface visible to the observer, such as
the front panel 12 or fascia 68 of the mass confinement cell 10
will generally include a molded and/or fabricated texture and/or
pattern in the deterioration resistant material. In various
embodiments of the present invention the exposed surface of the
landscaping product, such as the front panel 12 or fascia 68, will
have a natural earthen appearance simulating the texture and color
of natural earthen surfaces. For example in some embodiments, the
exposed surface of the front panel 12 or the surface of the fascia
68 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, the
front panel 12 or fascia 68 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 the front panel 12 or fascia 68, 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, the front panel 12 or fascia 68 may
further include a design, such as the appearance of multiple
bricks, stones, or blocks. See FIG. 20 for an example of a
multi-stone design. 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.
[0112] In various embodiments of the present invention the texture
of the front panel 12 or fascia 68 is produced by imaging an actual
natural surface, such as natural stone, brick or wood and producing
a mold that mimics that particular image. The imaging of the
natural surface can be performed by processes such as casting the
natural surface or by digital scanning the natural surface. When
casting the natural surface a mirror image of the surface can be
produced by preparing a solidifying material, such as silicone, and
casting it over the natural surface. Once the solidifying material
sets the newly casted mold is removed and an opposite image or
negative of the natural surface is produced. Once the casted mirror
image is produced, a mold or a mold insert manufactured from a
suitable mold material, such as aluminum, steel or a ceramic, can
be produced for mass manufacture. In various embodiments of the
present invention ceramic molds are produced to provide the desired
detail found in the natural surface which then can be transferred
to a more durable steel or aluminum mold for mass manufacture. One
source for such molds formed of ceramic materials is Arrow Pattern
and Foundry Company, 9725 South Industrial Drive, Bridgeview Ill.
Alternatively, a mold may be prepared by digitally scanning the
natural surface, such that the surface of a stone, brick or piece
of wood. Once scanned, a mold can be produced from a suitable mold
material for mass manufacture of the front panels or fascias having
a front surface supporting the scanned image.
[0113] As previously suggested, many embodiments of the present
invention have a molded or fabricated front panel 12, partial top
panel (not shown), fascia 68 and/or other portions of the mass
confinement cell 10 (e.g. endcaps and topcaps), that exhibit an
earthen appearance, crystalline appearance or other aesthetic
design. This may be accomplished in a number of ways including but
not limited to thermal molding, lamination and/or surface coating
(e.g. U.V. activated coating or polymer adhesion painting). For
example, in some embodiments of the present invention the texture
and color of the confinement cell 10 may be formed by thermal
molding one or more resins that include colors and other additives
in a mold that has a desired texture. Such a process may be
performed by any process known in the art, such as thermoforming,
extrusion, injection molding, structural foam molding (e.g. low
pressure multi-nozzle structural foam), vacuum molding or any
combination thereof. For example, one or more polymers, such as
HDPE, polypropylene or a polyester (e.g. Polyethylene terephthalate
(PET), polycarbonate), that includes one or more colors, fillers,
and/or additives (e.g. U.V. inhibitors) may be injected into a mold
that includes a desired shape and texture to form a front panel 12,
fascia 68 or other visible part of the mass confinement cell 10.
One example, of such a desirable material that may be utilized to
produce components of the present invention by thermal molding is a
bulk molding compound (BMC) or thermoset that includes one or more
polyester resins, glass fibers and other additives and is
manufactured and/or molded by Bulk Molding Compounds, Inc. 1600
Powis Court West, Chicago Ill. 60185 and Kenro Incorporated, a
Carlisle Company, 200 Industrial Drive, Fredonia, Wis. 53021. In
various embodiments, the texture may also be imprinted on the mass
confinement cell 10, 210 310 in a secondary process after formation
of one or more components of the confinement cell 10, 210, 310 by
rolling a die that imprints the texture on the surface of the
polymeric front panel 12, fascia 68 and/or other portion of the
cell 10.
[0114] 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 10 that are intended to have
the earthen appearance or other design. In various embodiments of
the present invention a sheet of polymeric material may include
natural or synthetic particles (e.g. granite, marble, aluminum
trihydrate, aluminum oxide, calcium oxide . . . ). Generally, in
the lamination process, the front panel 12 or fascia 68 may have a
sheet of polymeric material heat welded or adhered to the front
surface plastic of the front panel 12 or fascia 68. Such a
lamination step may happen in a secondary step after formation of
the front panel 12 or fascia 68. Alternatively, the lamination
plastic sheet may be inserted into the front side of a mold and
formed over the resin that is administered into the mold (e.g.
in-mold decoration). For example, a sheet of polymeric material may
be placed in the front end of an injection molding mold and
subsequently thermoformed or vacuum formed to the front surface of
the mold prior to filling the mold with resin when manufacturing
the front panel 12 or fascia 68. Next, melted resin is shot into
the injection mold, thereby integrating the laminated sheet into
the face and optionally top of the front panel 12 or fascia 68.
[0115] 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.
[0116] 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.
[0117] 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.
[0118] 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.
[0119] 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.
[0120] 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.
[0121] 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.
[0122] 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.
[0123] 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.
[0124] 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.
[0125] 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.dbd.C.dbd.O)
such as ketene and diphenylketene.
[0126] 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.
[0127] 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.
[0128] 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 10 after the surface of the cell, such as the
front panel 12, the fascia 68, the end cap 82 or the cell cap, 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 the mass confinement cell
10. It is noted that the polymer adhesion paint mixture should be
applied shortly after mixing; in some embodiments almost
immediately. One example of the types of polymeric paints that may
be utilized with embodiments of the present invention is a two
component polyurethane that generally includes a mix ratio of five
parts colored paint with one part crosslinker (e.g. XL-003
crosslinker or an isocynate). Two examples of two such polyurethane
based paints are as follows:
Example 1
TABLE-US-00001 [0129] HIGH SOLIDS ALLPHATIC POLYURETHANE 120 Series
DESCRIPTION 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
.degree. 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.degree. F. Cure Schedule: 30 min @
180.degree. F. Gloss 60.degree.: Flat to 96 VOC as
supplied-lbs/gallon: 3.0-3.6 VOC as applied-lbs/gallon: 2.9-3.5
Example 2
TABLE-US-00002 [0130] MEDIUM SOLIDS ALLPHATIC POLYURETHANE 121
Series DESCRIPTION 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 .degree. F. 78
Application Method: HVLP; Conv. Reduction for Application: 4-base;
1-XL009 5-base; 1-XL003 Pot Life: 2 hrs @ 70.degree. F. Cure
Schedule: 35 min @ 160.degree. F., Air Dry tack free 40 min Gloss
60.degree.: 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:
PRIME COATINGS
1002 Hickory Street
Pewaukee, Wis. 53072
[0131] www.primecoatings.net
Telephone: (262) 691-1930
[0132] 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 is 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.
[0133] 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.degree. F. and less
(e.g. 175.degree. F. to 220.degree. F.); in other embodiments
185.degree. F. and less (e.g. 150.degree. F. to 185.degree. F.);
and in still other embodiments 160.degree. F. and less (e.g.
100.degree. F. to 150.degree. 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.
[0134] It is noted that the solid surface coating, 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. 22a-b and 23a-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. 22a and 22b depict a top view and bottom
view of an edger and FIGS. 23a and 23b 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.
[0135] As previously indicated the mass confinement cells 10 of the
present invention generally include one or more side panels 16 that
engage and extend from the front panel 12 back to engage with a
back panel 14. As depicted generally in a number of the FIGS.,
various embodiments of the present invention include side panels 16
engaging the front panel 12 at angles to provide for a tapering of
the confinement cell as it moves back in width. The angle formed
between the front panel 12 and side panel 16 is generally less that
90.degree. when the front panel 12 is substantially straight and
less than 150.degree. when the front panel 12 is rounded or
beveled. In other embodiments, the angle is between about
45.degree. and 85.degree. for substantially straight front panels
12 and between 60.degree. and 110.degree. for beveled and rounded
front panels 12. In various embodiments the side panels 16 may
extend from the front panel 12 at angles that would allow them to
engage each other at the back of the confinement cell, thereby
forming the back panel 14 and chamber 18 by their engagement (e.g.
a triangle or diamond configuration). Finally, in various
embodiments, the top edge of the side panels 16 may slightly slope
down from front to back, thereby providing a back end of the
confinement cell that is slightly lower than the front of the
confinement cell (e.g. 0.5-10 mm).
[0136] Furthermore, the side panels 16 may further include one or
more grid fasteners (not shown), wherein geogrid can thread over
and secure when utilized between rows of confinement cells 10. In
other embodiments, the grid fastener may include an overhanging
portion (not shown) that the grid can slide under, thereby
inhibiting vertical movement of the grid once in position. The side
panels 16 may further include lightening apertures (not shown).
Such apertures allow for reduction of resin and thereby make the
product more light-weight and cost efficient.
[0137] In various embodiments of the present invention, the mass
confinement cell 10 further includes a partial top panel that
extends from the front panel 12 or fascia 68 that is exposed when a
retaining wall is constructed. The partial top panel assists to
close or partially close the top front portion of the confinement
cell 10 that may be exposed to the outer environment. In various
embodiments, the mass confinement cells 10 include a partial top
panel that extends from the front panel 12 or fascia 68 back to no
more than 75% of the depth of the confinement cell 10. It is noted
that cell depth is measured from the front panel 12 or fascia 68 to
the back panel 16 of the confinement cell 10. In other embodiments
of the present invention, such a partial top panel extends from the
front panel 12 or fascia 68 no more than 50% of the depth of the
confinement cell. In yet other embodiments the partial top panel
extends from the front panel 12 or fascia 68 no more than 35% of
the depth of the confinement cell (e.g. 5% to 30%). Such a partial
top panel provides for at least a partial sealing of the
confinement cell at the top front portion, of which may be exposed
when the retaining wall is constructed in a configuration wherein
the wall inclines back toward the surface or slope intended to be
protected. FIG. 24 depicts one embodiment of the present invention
wherein the front panel includes one embodiment of a front panel 12
with a partial top panel 20. It is noted that in various
embodiments the top panel may further include one or more planting
apertures 94 (e.g. see FIG. 25) that may allow plant growth from
the top surface of the confinement cell 10. As previously
suggested, the open top and bottom of each mass confinement cell 10
allows for the receiving and commingling of fill material that may
flow from and through the confinement cell 10 to one or more
adjacent cells 10 below or above.
[0138] The partial top panel may further include optional top side
panels 96 that extend downward from the partial top panel and may
extend over or within the side panels of the confinement cell (not
shown). Also, various embodiments, as depicted in FIG. 26 may also
include more than two securing mechanisms 22 positioned at various
positions in the front panel 12. This is advantageous if partial
cells are required. For example, the confinement cell 10 may be cut
and a peg of the side panel 16 may be secured into the additional
socket of the securing mechanism of the front panel to secure the
front panel 12 to the rest of the confinement cell 10. By providing
additional securing mechanisms 22, the cutting of the front panel
12 still allows for the remaining portion of the front panel 12 to
have two outer securing mechanisms 22 for securing a side panel 16
to the cut front panel 12. Partial confinement cells 10 may further
include one or more shorter stabilizing partitions to assist in
securing the two halves of the cell together and further
stabilizing the confinement cell 10 after cutting.
[0139] It is noted that in some embodiments, the partial top panel
20, as depicted in FIGS. 24-26 may extend back from the top edge of
the front panel 12 to the top edge of a partition 40. Therefore, an
example of such an embodiment would provide for a partial top panel
20 extending from the front panel 12 to the partition 40 on the
mass confinement cell of FIG. 10. In some embodiments, ribbing or
inner stability ridges (not shown) may be positioned between the
front panel 12 and partition 40 to provide additional stability to
the structure.
[0140] Also, in various embodiments, two or more of the panels may
be adjoined to other panels of the cell with living hinges. Living
hinges generally comprise a thin flexible plastic (e.g. HDPE,
polypropylene) that can bend into position without breaking when
the panels are formed into an assembly position to form the
chamber.
[0141] It is further noted that the mass confinement cell
embodiments may further include a load cell 98 positioned within
the front panel 12, side panels 16 and optionally a back panel 14.
A further description of load cell embodiments is described below.
Such load cells positioned in and/or attached to the confinement
cell 10 may be added to provide additional structural support to
the cell. FIG. 27 depicts one embodiment of a load cell 98 that may
be secured to the confinement cell 10 by one or more load cell
fasteners 100. Generally, the load cell 98 is a cylinder that when
attached to the confinement cell 10 forms and/or resides within the
continuous chamber 18. 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 embodiment of
FIG. 29 the load cell 98 includes a substantially straight back
panel 14 integrally adjoined to a rounded front section 102. The
back panel 14 may further include ribs 30 that may be position on
the front and/or back of the back panel 14 to provide additional
stability. The load cell 98 may further include an anchoring ridge
104 or aperture (not shown) that may be utilized to accept the
anchoring devices for confinement cell 10 positioning and overturn
prevention or reduction.
[0142] The load cell fasteners 100 may be any fastening device or
material that securely adjoins the load cell 98 to the confinement
cell 10. In one embodiment, as depicted in FIG. 29 the load cell
fastener 100 is one or more projections that extend inward from the
outer edge of the anchoring ridge 104. In operation, the load cell
100 is inserted into one or more apertures in the confinement cell
10 so that the load cell fastener 100 engages with a load cell
aperture (not shown) or ridge on the side panels 16.
[0143] The load cell may further include one or more grid fasteners
106 for securing and positioning geogrid when it is utilized in a
wall structure. The grid fastener 106 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.
[0144] In some embodiments of the confinement cells 10 of the
present invention, a plurality of load cells 98 may be adjoined
together and secured to the larger frame of the cell to reduce the
flow forces of the fill materials in the larger walls. The load
cells of the multi-load 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.
[0145] Additionally, in other embodiments, the load cell may be
split vertically 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 confinement cell 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.
[0146] The mass confinement cell 10 of the various embodiments of
the present invention may further be fitted with an end cap 82 to
finish the end of a wall, provide an end finish for a sharp turn
(e.g. 90.degree. 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 an end cap 82 is depicted
in FIGS. 28a and 28b. In most embodiments, the end cap 82 will
include a back surface 84 and side surface 86 that is textured and
colored similar to the front panel 12 or fascia 68 of the mass
confinement cell 10. Additionally, the top surface 88 of the endcap
82 may include a texture and color similar to the front panel 12 or
fascia 68 of the mass confinement cell 10. In one embodiment, as
depicted in FIG. 28b, the end cap 82 includes one or more securing
pegs 90 that may be inserted into lightening apertures (not shown)
or other attachment points positioned in the side panels 16 of a
confinement cell 10. The end cap 82 may also include ribs 30 to
provide stability to the structure. FIG. 29 depicts one embodiment
of a fully assembled mass confinement cell 10 that includes end
caps 82. The embodiment of FIG. 29 includes a front panel 12 having
load bearing members 92, back panel 14, side panels 16, fascia 68
and two endcaps 82.
[0147] FIGS. 30a-b and 31a-b depict various embodiments of top
covers 108 and bottom covers 110, which are configured and adapted
to securely fit over or under embodiments of the mass confinement
cell 10 of the present invention. Generally, in some embodiments,
the top covers 108 and bottom covers 110 utilized in constructing
some of the retaining walls of the present invention are at the
very top of the wall and very bottom of the wall to at least
partially seal the continuous chamber channels. However, the use of
such covers 108, 110 at intermediate locations through the wall may
also be performed. In various embodiments of the present invention,
the top cover 108 generally includes a continuous top panel 112
that includes optional overlapping edges 114, which overlap
securely over the outside side and back panels 14, 16. In some
embodiments of the invention, the overlapping edges 114 may be
present around the entire perimeter of the top of the confinement
cell 10. Alternately, a forward extending apron 116 may be
positioned at the front of the top cover 108 and utilized to secure
the cover 108 to the adjacent confinement cell 10 below by
inserting the apron 116 under the partial top panel of the cell 10
below.
[0148] Embodiments of the bottom covers 110 of the present
invention, as depicted in FIGS. 31a-b, may include a bottom panel
118 with attached bottom side walls 120 extending around the
perimeter of bottom of the cell. The side walls 120 may be
configured to overlap the front, back and side panels 12, 14, 16 or
configured to nest within the front, back and side panels 12, 14
and 16. In other embodiments, as depicted in FIG. 31a, the
overlapping sides may include an optional channel 122 for receiving
and retaining the front, side and back panels 12, 14, and 16 of the
adjacent confinement cell 10 above. Alternatively, the top covers
108 and/or bottom covers 110 may include only a top panel 112 or
bottom panel 118 that nest and optionally secure into place just
within the front panel 12, back panel 14 and side panels 14 of the
confinement cell 10. Additionally, the top cover 108 may include
one or more planting apertures (not shown) for allowing the growth
of vegetation from the mass confinement cell.
[0149] FIGS. 32-34 depict other embodiments of the present
invention wherein the mass confinement cells 10 include an
interconnecting device 124. It is noted that in the mass
confinement cell 10 embodiments, the interconnecting device 124 may
be a securing mechanism as described above or a variation thereof.
In various embodiments, as depicted in FIG. 32 the interconnecting
device 124 includes a peg and socket system having one or more
insertable pegs 32 to adjoin two or more confinement cells by
inserting the pegs 32 into a socket 38. The sockets 38 are
generally positioned on an edge or just inside the edge of the
front, side and/or back panels 12, 16, 14. The sockets may be
integral to the front or back panels 12, 14 or may be secured to
the panels 12, 16, 14 in any manner known in the art. The pegs 32
are configured to be securely receivable by the sockets and may be
configured to swivel the confinement cell 10. The insertable pegs
32 can be made of any shape and size, which can be securely fit
into the sockets.
[0150] Alternatively, in one embodiment of the present invention
side by side adjacent confinement cells 10 may be adjoined with a
clipping device 126. In one embodiment the clipping device 126 may
be configured in a U shape and sized to snuggly fit over the side
panels 16 of two adjacent confinement cells. An illustration of one
embodiment of a clipping device is depicted in FIG. 33.
[0151] FIG. 34 depicts an additional embodiment of the present
invention, similar to hook attachments, wherein the mass
confinement cell 10 includes an interlocking feature that comprises
a hook or peg 128. An optional pocket (not shown) may also be
placed in the confinement cell 10 for receiving the hook 128 from
adjacent confinement cells 10. In such an embodiment one or more
hooks or pegs 128 extend from one side panel 16 of a mass
confinement cell 10 and may be inserted over the opposite side
panel 16 of an adjacent cell 10. Such interlocking mechanisms
provides for a overall secure retaining wall structure by reducing
the amount of movement that may occur during filling with unsecured
individual cells.
[0152] 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 nesting the cells within each other or by separating
the front panel 12, back panels 14 and/or side panels 16 and
stacking and/or nesting the respective panels when in transport or
storage. FIG. 35 depicts a plurality of cell that are nested and
FIG. 36 depicts a plurality of partial mass confinement cells 10
that do not include an attached front panel positioned in a nested
position. Other nesting positions or stacked positions may also be
utilized with various embodiments of the present invention.
[0153] The mass confinement cell 10 of the present invention may
also be utilized with other wall stabilizing products to secure and
stabilize a structure constructed of such cells 10. For example,
FIG. 37 depicts an embodiment of a mass confinement cell 10 wherein
a structural grid 130 is attached to confinement cell 10 (e.g.
attachment to the upper front panel 12, back panel 14, partial top
panel 20, or bottom panel (not shown) or peg extensions 48 on the
back panel 14 or partition 40. The grid 130 is buried behind the
wall constructed of the confinement cells of the present invention
and acts to support and stabilize the aggregate placed behind the
wall and prevent the wall from moving forward away from the
embankment it is protecting.
[0154] In an alternative embodiment, the mass confinement cell 10
may be utilized with and/or secured to a cellular confinement
system or block confinement system (e.g. A commercially available
system is the Geo-web.RTM. plastic web soil confinement system or
the Geo-block.RTM. system, sold by Presto Products, Incorporated,
P.O. Box 2399, Appleton, Wis. 54913) thereby providing a retaining
wall front to an erosion control structure. Suitable cell
confinement systems are well known in the art and are generally
disclosed in U.S. Pat. No. 6,296,924, issued on Oct. 2, 1001, U.S.
Pat. No. 5,927,506, issued on Jul. 27, 1999, U.S. Pat. No.
5,449,543, issued on Sep. 12, 1995 and U.S. Pat. No. 4,778,309,
issued on Oct. 18, 1988, the entire contents of which are
incorporated by reference herein.
[0155] In various embodiments of the present invention, a plurality
of confinement cells 10, and/or multiunit confinement cells or
partial components of the cells 10 may be positioned upon a base of
block confinement systems, such as Geo-block.RTM., and/or operably
secured to one or more cell confinement systems, such as
Geo-web.RTM.. The intermingling of the confinement cells 10 of the
present invention with the cell or block confinement systems
provides further stability to a retaining wall structure, as well
as allows for the construction of an aesthetically pleasing
wall.
[0156] FIG. 38 depicts one embodiment of the present invention
wherein a plurality of partial confinement cells including a front
panel 12 adjoined to two side panels are positioned adjacent to and
adjoined to a cell confinement system 132 with a cell confinement
fastener 134. The front panel 12 may further include a partial top
panel 20. In various embodiments the front panel may be adjoined
directly to the cellular confinement system (not shown). In the
embodiment depicted in FIG. 38, the front panel 12 and side panels
16 are positioned in front of one or more cells of the front
cellular wall of a cell confinement system 132 and secured. If side
panels are present the side panels may be secured to one or more
cells of the cellular confinement system. The securing of the front
panel 12 and/or side panels to the front cellular confinement
system 132 may form a chamber that may be filled with one or more
fill materials.
[0157] In various embodiments, the cell confinement fastener 134
may be any form that extends from one or more panels 12, 14, 16 and
over, under or through the front of the cellular confinement system
132 to thereby hold the panel(s) 12, 14, 16 in position. For
example, in one embodiment, as depicted in FIG. 38, the front panel
12, side panels 16 or back panel 14 may be secured to the cell
confinement system 132 by one or more U-type clips that extend from
the front panel 12, side panels 16 or back panel 14 between two
layers of cell confinement systems 132 and up, down and/or through
a cell of a cell confinement system 132 to secure the confinement
cell 10 to the cell confinement system 132. In other embodiments,
pegs may be used to secure the partial cells 10 to the cell
confinement system 118 by inserting a peg into threads that extend
from the cell 10 and over the front face of the front of the
cellular confinement system 132. Other examples of cell confinement
fasteners 134 may include any securing mechanism, such as tabs,
hooks, clips, cables, rods and the like.
[0158] Another cell confinement fastener 134 may further include
one or more reinforcing members 136, such as cables, tendons and/or
bars. Examples of such reinforcing members are disclosed in U.S.
Pat. Nos. 5,449,543 and 5,927,906, the entire contents and
description of which are incorporated by reference herein. In such
embodiments, as depicted in FIG. 39 the reinforcing members 124 may
be tendons that extend through the cellular confinement system 132
to secure the confinement cells 10. The reinforcing members 136,
such as tendons, may also be extended through the side walls 16 of
the confinement cells 10 to secure adjacent cells 10 to each other.
In such embodiments, reinforcing members 136 that extend through
the side walls 16 of the cells 10 may be intersected and adjoined
to tendons that extend through the cellular confinement systems
132. Such intersection and adjoinment may be secured with fasteners
138 such as clips, wire or the fasteners disclosed in U.S. Pat.
Nos. 5,449,543 and 5,927,906. The cells 10 and cellular confinement
systems 132 may also be further secured and reinforced with
fasteners and securing rods as described in U.S. Pat. Nos.
5,449,543 and 5,927,906.
[0159] As previously mentioned, the mass confinement cells of the
present invention may be manufactured from a deterioration
resistant, substantially rigid composite or polymeric material
including, but not limited to, plastic (e.g. recycled or virgin),
thermoset, a rubber composition, fiberglass, or any other similar
material or a combination thereof. Preferable materials comprise
light-weight and slightly flexible polymers, such as high and low
density polyethylene or polypropylene or thermosets, such as the
polyester bulk molding compound produced by BMC, Inc. However,
other plastics and thermosets 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. 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 be comprised of 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.
[0160] 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 (e.g. low pressure multi-nozzle structural foam),
extrusion, thermo-forming, compression molding, roto-molding and
the like, the molds may include any type of design or shape.
Furthermore, the front panels of the mass confinement cell 10,
could be molded in almost any type of configuration. In one
embodiment, multiple mass confinement cells 10 could be molded to
include designs that, when positioned on a retaining wall, would
complete a larger single design, such as the spelling of a company
or school name in large letters or the completion of a large image.
Also, since the present invention may be manufactured from and/or
include a number of different products, such as plastic, a rubber
composition or fiberglass, and may include any color or a multitude
of colors. For example, a retaining wall installed in a beach
setting may be manufactured of a plastic or rubber product and be
colored in so that organic matter wash up on it would not show up
as readily or may take on the appearance of sand.
[0161] 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.
[0162] As previously suggested the environment resistant mass
confinement cell is utilized in the construction of any type of
wall, border or revetment. In application, the confinement cells 10
are provided in a desired and assembled form. For various
embodiments of the confinement cells 10 some assembly may be
required, such as inserting the T-hooks or pegs into the T-slots or
sockets or attaching the load cell 98 and fascia 68 to a front,
back and/or side panels 12, 14, 16. Next, a foundation is prepared
in the area that the wall, border or revetment is to be
constructed. The foundation preferably is flat, compacted and level
and can accommodate one or more mass confinement cells 10 and
optionally one or more cellular confinement systems. In various
embodiments, one or more courses of confinement cells 10 may be
partially submerged or totally submerged below the earth surface to
provide wall stability. Once a foundation is completed, a first row
is laid by positioning the confinement cells 10 and optionally the
cellular confinement systems in their proper position side by side
and filling each individual confinement cell 10 with a fill
material while back filling behind the row or filling the cellular
confinement systems positioned behind the cells 10 until the row is
completed. A fill material compacting device may be utilized while
or after filling to ensure stability of the fill material as the
wall is constructed. For example, a packing device may be utilized
to pack the fill material after filling each row of confinement
cells 10 and/or cellular confinement system. The chamber 18 is
normally filled with materials such as sand, crushed rock, pea
rock, gravel, dirt, cement, concrete or other beneficial materials
to provide weight and structure stability to the mass confinement
cell 10 and the entire retaining wall. The filling of the mass
confinement cell 10 gives it the added weight that it needs to
retain its structure and hold it in place. A funneling device (not
shown) may be utilized, which fits securely into the openings or
apertures of the mass confinement cell 10 to guide fill into the
chamber 18 of the cell 10. The first row and subsequent rows may be
straight or curved. Upon completion of the first row, additional
rows are constructed by placing the mass confinement cells 10 and
optionally the cellular confinement system 132, in the proper
position and performing the same filling and back filling process
until a continuous chamber retaining wall is completed. It is noted
that with the continuous chamber system of the present invention,
multiple rows can be secured in place before filling and/or
packing. However, it is recommended that filling and packing be
done regularly (e.g. row by row) to ensure proper packing of the
fill material.
[0163] Generally, a continuous chamber system retaining wall
includes stacked rows wherein individual confinement cells 10 are
placed adjacent to one another thereby eliminating or minimizing
cracks or gaps in the wall. Rows of mass confinement cells 10 may
be positioned directly over other rows of mass confinement cells 10
wherein the cells 10 of each row are positioned directly over other
cells 10. However, many embodiments of the present invention
provide a constructed wall wherein the mass confinement cells 10
are staggered in alternating rows as depicted in FIGS. 40a-b. It is
also noted, that the constructed wall may further be secured to the
slope and the aggregate behind the wall can be further stabilized
by positioning geogrid between rows of mass confinement cells 10.
Such action may be performed between each row or alternated every
2-15 rows, and optionally every 3-10 rows.
[0164] Each mass confinement cell 10 placed in the retaining wall
is configured to retain and seal the contents of the fill material
back towards the slope when the wall has been properly constructed.
This may be further accomplished by applying top covers 108 and/or
bottom covers 110 that at least partially seal the continuous
chamber system. Alternatively, vegetation may be planted on the top
row of the retaining wall to assist in sealing in the contents.
[0165] Furthermore, in various embodiments, the mass confinement
cells 10 of the upper rows may be further positioned into place by
an overlap of the back of confinement cells 10 of lower rows if a
retaining flange or peg extensions 48 are included on the
confinement cell 10. In the alternative or additionally, each
individual confinement cell 10 may be locked into position with
adjacent cells 10 if spools or reinforcing members and apertures,
clipping devices 126 or hooks 128 are present with the confinement
cell 10.
[0166] As previously mentioned, upon completion of the top row of
the retaining wall, a cover, aesthetic top border or cell cap 138
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 a cell cap 138, as depicted in FIG. 41, may be
polygonal in shape and include textured and designed faces on both
the front panels 12, back panels 14 and top of the cell cap 138.
The cell caps 138 may further include pegs (not shown), similar to
those depicted in the previous confinement cell embodiments, that
may be utilized to secure the cell cap 138 to the mass confinement
cells 10 positioned below. Alternatively, the cell caps 138 may be
secured to the mass confinement cells 10 below by any means known
in the art, such as clips, tacks, screws, rivets, adhesives or the
like. The cell caps 138 may be filled with a fill material, similar
to the other embodiments of the present invention, or may be a
thinner cap 138 that includes a plurality of reinforcing partitions
or ribs 30.
[0167] FIG. 42 depicts another embodiment of a cell cap 138 that
may be utilized with the mass confinement cell systems of the
present invention. The cell cap 138 of the this embodiment is
intended to wholly or partially cover the continuous flow chambers
18 of the confinement cells 10 positioned below when finishing the
top course of a retaining wall or edges of a revetment. The cell
cap 138 of this embodiment may extend a distance from the front
edge, or slightly overhanging the front edge of the mass
confinement cell 10 back over the top of the top course of
confinement cells 10. In various embodiments, the cell cap 138 may
extend back a distance of approximately between 5% to 110% of the
confinement cell 10. In various embodiments, this distance may
translate to approximately 5 cm to 125 cm.
[0168] The cell cap 138 of this embodiment depicted in FIG. 42
generally includes a top cap 140, as depicted in FIG. 43a, that is
engageable with a confinement cell cover 142, as depicted in FIG.
43b. The cell cover 142 generally engages the confinement cell 10
positioned below and thereby is intended to lock the cell cap 138
into position on the wall or revetment. The cell cover 142 can
engage the mass confinement cell 10 positioned below utilizing one
or more cover fasteners 144 that may engage the confinement cell at
any applicable surface (e.g. the front panel, side panels,
partitions). The cover fasteners 144 may be any type of fastening
device, such as pegs, rivets, screws, adhesives, hooks, snaps, tabs
and any other means that will secure the cell cap 138 to the cell
confinement cells 10. The top cap 140 of this embodiment engages
the cell cover 142 by any means to adequately secure the top cap
140 to the cell cover 142. For example, snaps, pegs, tabs,
adhesives and any other means to fasten and secure the top cap may
be utilized. Additionally, the top cap 140 may further include one
or more ribs 30 to provide additional structural support to the top
cap 140. The cell cap 138 may further include one or more end caps
146 that may be secured to the ends of the cell cap 138 to close
the outer edges. See FIGS. 43c-d for a front and back view of the
endcap 146.
[0169] FIG. 44 depicts another embodiment of a cell cap 138 that
may be utilized with the mass confinement cells 10 of the present
invention. The cell cap 138 of this embodiment generally includes a
top cap 140 adjoined to a cell cover 142. The top cap 140 may be
integrally adjoined to the cell cover 142 or may be a separate
component attachable to the cell cover 142. The top cap 138 may
further include a plurality of ribs 30 to provide additional
stability and structure. Similar to the previous embodiment, the
cell cover 142 can engage the mass confinement cell 10 positioned
below utilizing one or more cover fasteners (not shown) that may
engage the confinement cell at any applicable surface (e.g. the
front panel, side panels, partitions). The cover fasteners may be
any type of fastening device, such as pegs, rivets, screws,
adhesives, hooks, snaps, tabs and any other means that will secure
the cell cap 138 to the cell confinement cells 10. Additionally,
the cell cap 138 of various embodiments may further include one or
more extension flaps 143 that bridge the gaps between adjacent cell
caps 138. The extension flaps 143 may be stationary and integrally
attached or may be moveable to retract or extend, thereby providing
less or more length to each flap 143. In various embodiments, the
extension flaps may be placed on a track that allows for the
extension or refraction of the flaps 143.
[0170] FIG. 45 depicts yet another embodiment of a cell cap 138
that may be utilized with the mass confinement cells 10 of the
present invention. The cell cap 138 of this embodiment generally
includes a top cap 140 adjoined to a cell cover 142 and one or more
anchoring devices. The anchoring devices in this embodiment may
include one or more arms 148 that are operably adjoined to one or
more peg extensions 48. The peg extensions 48 may further be
locking peg 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 10 positioned below. Additionally,
the arms 148 may be integrally adjoined to the top cap 140 or
adjoined with living hinges 150 and securing snaps, which would
allow for the cell cap 138 to be transported and/or stored in a
flat or nested configuration. Similar to the previous embodiments,
the cell cover 142 can engage the mass confinement cell 10
positioned below utilizing one or more cover fasteners (not shown)
that may engage the confinement cell at any applicable surface
(e.g. the front panel, side panels, partitions). The cover
fasteners may be any type of fastening device, such as pegs,
rivets, screws, adhesives, hooks, snaps, tabs and any other means
that will secure the cell cap 138 to the cell confinement cells
10.
[0171] The top cap 140 of many embodiments will include the texture
and color of all the surfaces intended to be exposed on the front
panel 12 or fascia 68 of the cell confinement systems 10 to provide
a natural earthen appearance and/or design. The top cap 140 may
further include a plurality of ribs 28 to stabilize the top cap 142
and prevent crushing or damaging. The top cap 142 and top cover 142
in a number of embodiments may be polygonal in shape, thereby
allowing for a continuous cell cap 138 alignment over the length of
a wall or revetment. The polygonal shape also allows for a
continuous coverage when curving a wall structure.
[0172] 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.RTM., Anchor.RTM. Wall
Systems or Allan Block.RTM.. 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.
[0173] Finally, 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.
[0174] 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.
* * * * *
References