Note: Descriptions are shown in the official language in which they were submitted.
METHODS FOR FORMING NOISE ABSORBING
BARRIER WALLS AND RELATED FORMS
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not applicable.
BACKGROUND OF THE INVENTION
1. The Field of the Invention
[0002] The present invention relates to methods for forming noise absorbing
barrier walls and
related forms.
2. The Relevant Technology
[0003] Noise absorbing barrier walls are commonly placed along one or both
opposing sides
of highways or freeway that are located adjacent to residential areas. The
noise absorbing barrier
walls have a first side formed of a noise absorbing material and an opposing
second side formed
of concrete. The concrete second side provides structural support and
stability for the noise
absorbing first side. During use, the noise absorbing barrier walls are
erected so that the noise
absorbing first side faces toward the highway or freeway so that the noise
absorbing material
assists in absorbing noise generated by vehicles traveling along the highway
or freeway.
10004] Noise absorbing barrier walls are typically formed by using a pan
mold having an
enlarged horizontal floor with a short encircling sidewall upstanding from the
floor. The floor
and the encircling sidewall partially bound a compartment having an open top.
During
manufacture, a layer of noise absorbing material is first deposited on top of
the floor within the
compartment. A layer of concrete is then poured over the layer of the noise
absorbing material
within the compartment. The materials are then allowed to harden together so
that the exterior
surface of the noise absorbing side of the barrier wall is formed against that
floor and the exterior
surface of the concrete side of the barrier wall is openly exposed. Once the
materials have
hardened into a structural wall, the noise absorbing barrier wall is removed
from the pan mold
and is ready to be erected along a highway or freeway.
[0005] Although the above mold and method are useful, they have some
shortcomings. For
example, as a result of the enlarged floor of the pan mold being horizontally
disposed as the
materials harden, the mold occupies a large area of space. This can make it
difficult to
simultaneously produce multiple noise absorbing barrier walls.
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[0006] In addition, it can be desirable to have an aesthetic design formed
on each opposing
side of the noise absorbing barrier wall. On the noise absorbing side of the
barrier wall, the
design can be produced by forming the design on the interior surface of the
floor. In turn, the
design is transferred to the noise absorbing side of the barrier wall as the
material rests and
hardens on the floor. However, the concrete side of the barrier wall is openly
exposed, making it
difficult to produce the design on that side. Although a cover could be placed
on top of the
mold, it is very difficult to both precisely fill the mold with concrete and
precisely attach a cover
to the mold so that a design formed on the interior surface of the cover is
transferred to the
concrete side of the barrier wall. That is, if the large surface area of the
concrete side of the
barrier wall is too high or too low, the cover can either be difficult to
attach or fail to transfer the
design to the barrier wall.
[0007] Another problem with using pan molds to form noise absorbing walls
is that it takes
an extended period of time before the barrier walls can be demolded and
erected. That is, it is
typically desirable to remove the barrier walls from the molds as soon as
possible so that the
molds can be reused to form a new barrier wall. However, barrier walls that
are in a horizontal
position are in a weaker or more fragile state, relative to walls that are
vertically erected. As
such, barrier walls in a horizontal orientation must be left for an extended
period of time to cure
and harden before they can be demolded and moved to a vertical storage
position. Other
shortcomings also exist.
[0008] Accordingly, what is needed in the art are methods and/or forms that
overcome one or
more of the current problems associated with producing noise absorbing barrier
walls.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Various embodiments of the present invention will now be discussed
with reference to
the appended drawings. It is appreciated that these drawings depict only
typical embodiments of
the invention and are therefore not to be considered limiting of its scope.
[0010] Figure 1 is a front perspective view of a form for forming a noise
absorbing barrier
wall with the mold thereof in a vertical orientation;
[0011] Figure 2 is a rear perspective view of the form shown in Figure 1;
[0012] Figure 3 is a partially exploded view of the form shown in Figure 1;
[0013] Figure 4 is a partially exploded view of the mold of the form shown
in Figure 3;
[0014] Figure 5 is a partially exploded view of the body of the mold shown
in Figure 4;
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[0015] Figure 6 is a front perspective view of the form shown in Figure 1
with the mold
thereof rotated to a horizontal orientation;
[0016] Figure 7 is a perspective view of the form shown in Figure 6 with
the front wall of the
mold being removed;
[0017] Figure 8 is a perspective view of the form shown in Figure 7 with a
noise absorbing
material and a cementitious material disposed within the compartment of the
mold;
[0018] Figure 9 is a perspective view of the form shown in Figure 7 with
the front wall of the
mold replaced and the mold rotated to the vertical orientation;
[0019] Figure 10 is a perspective view of the form shown in Figure 9 with
an additional layer
of cementitious material deposited within the compartment;
[0020] Figure 11 is a perspective view of the hardened noise absorbing
barrier wall removed
from the form shown in Figure 11; and
[0021] Figure 12 is a top perspective view of the form shown in Figure 8
with the prior noise
absorbing material replaced with a prefabricated panel formed from a noise
absorbing material.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Before describing the present disclosure in detail, it is to be
understood that this
disclosure is not limited to parameters of the particularly exemplified
systems, methods,
apparatus, products, processes, compositions, and/or kits, which may, of
course, vary. It is also
to be understood that the terminology used herein is only for the purpose of
describing particular
embodiments of the present disclosure, and is not necessarily intended to
limit the scope of the
disclosure in any particular manner. Thus, while the present disclosure will
be described in
detail with reference to specific embodiments, features, aspects,
configurations, etc., the
descriptions are illustrative and are not to be construed as limiting the
scope of the claimed
invention. Various modifications can be made to the illustrated embodiments,
features, aspects,
configurations, etc. without departing from the spirit and scope of the
invention as defined by the
claims. Thus, while various aspects and embodiments have been disclosed
herein, other aspects
and embodiments are contemplated.
[0023] Unless defined otherwise, all technical and scientific terms used
herein have the same
meaning as commonly understood by one of ordinary skill in the art to which
the present
disclosure pertains. While a number of methods and apparatus similar or
equivalent to those
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described herein can be used in the practice of the present disclosure, only
certain exemplary
methods and apparatus are described herein.
[0024] Various aspects of the present disclosure, including devices,
systems, methods, etc.,
may be illustrated with reference to one or more exemplary embodiments or
implementations.
As used herein, the terms "embodiment," "alternative embodiment" and/or
"exemplary
implementation" means "serving as an example, instance, or illustration," and
should not
necessarily be construed as preferred or advantageous over other embodiments
or
implementations disclosed herein. In addition, reference to an
"implementation" of the present
disclosure or invention includes a specific reference to one or more
embodiments thereof, and
vice versa, and is intended to provide illustrative examples without limiting
the scope of the
invention, which is indicated by the appended claims rather than by the
following description.
[0025] It will be noted that, as used in this specification and the
appended claims, the singular
forms "a," "an" and "the" include plural referents unless the content clearly
dictates otherwise.
Thus, for example, reference to a "cylinder" includes one, two, or more
cylinders.
[0026] As used throughout this application the words "can" and "may" are
used in a
permissive sense (i.e., meaning having the potential to), rather than the
mandatory sense (i.e.,
meaning must). Additionally, the terms "including," "having," "involving,"
"containing,"
"characterized by," variants thereof (e.g., "includes," "has," and "involves,"
"contains," etc.),
and similar terms as used herein, including in the claims, shall be inclusive
and/or open-ended,
shall have the same meaning as the word "comprising" and variants thereof
(e.g., "comprise" and
"comprises"), and do not exclude additional, un-recited elements or method
steps, illustratively.
[0027] Various aspects of the present disclosure can be illustrated by
describing components
that are coupled, attached, connected, and/or joined together. As used herein,
the terms
"coupled", "attached", "connected," and/or "joined" are used to indicate
either a direct
connection between two components or, where appropriate, an indirect
connection to one another
through intervening or intermediate components. In contrast, when a component
is referred to as
being "directly coupled", "directly attached", "directly connected," and/or
"directly joined" to
another component, no intervening elements are present or contemplated. Thus,
as used herein,
the terms "connection," "connected," and the like do not necessarily imply
direct contact
between the two or more elements. In addition, components that are coupled,
attached,
connected, and/or joined together are not necessarily (reversibly or
permanently) secured to one
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CA 3002249 2018-04-25
another. For instance, coupling, attaching, connecting, and/or joining can
comprise placing,
positioning, and/or disposing the components together or otherwise adjacent in
some
implementations.
[0028] As used herein, directional and/or arbitrary terms, such as "top,"
"bottom," "front,"
"back," "left," "right," "up," "down," "upper," "lower," "inner," "outer,"
"internal," "external,"
"interior," "exterior," "proximal," "distal" and the like can be used solely
to indicate relative
directions and/or orientations and may not otherwise be intended to limit the
scope of the
disclosure, including the specification, invention, and/or claims.
[0029] Where possible, like numbering of elements have been used in various
figures. In
addition, similar elements and/or elements having similar functions may be
designated by similar
numbering (e.g., element "10" and element "210.") Furthermore, alternative
configurations of a
particular element may each include separate letters appended to the element
number.
Accordingly, an appended letter can be used to designate an alternative
design, structure,
function, implementation, and/or embodiment of an element or feature without
an appended
letter. Similarly, multiple instances of an element and or sub-elements of a
parent element may
each include separate letters appended to the element number. In each case,
the element label
may be used without an appended letter to generally refer to instances of the
element or any one
of the alternative elements. Element labels including an appended letter can
be used to refer to a
specific instance of the element or to distinguish or draw attention to
multiple uses of the
element. However, element labels including an appended letter are not meant to
be limited to the
specific and/or particular embodiment(s) in which they are illustrated. In
other words, reference
to a specific feature in relation to one embodiment should not be construed as
being limited to
applications only within said embodiment.
[0030] It will also be appreciated that where a range of values (e.g., less
than, greater than, at
least, and/or up to a certain value, and/or between two recited values) is
disclosed or recited, any
specific value or range of values falling within the disclosed range of values
is likewise disclosed
and contemplated herein. Thus, disclosure of an illustrative measurement or
distance less than or
equal to about 10 units or between 0 and 10 units includes, illustratively, a
specific disclosure of:
(i) a measurement of 9 units, 5 units, 1 units, or any other value between 0
and 10 units,
including 0 units and/or 10 units; and/or (ii) a measurement between 9 units
and 1 units, between
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8 units and 2 units, between 6 units and 4 units, and/or any other range of
values between 0 and
units.
[0031] It is also noted that systems, methods, apparatus, devices,
products, processes,
compositions, and/or kits, etc., according to certain embodiments of the
present invention may
include, incorporate, or otherwise comprise properties, features, aspects,
steps, components,
members, and/or elements described in other embodiments disclosed and/or
described herein.
Thus, reference to a specific feature, aspect, steps, component, member,
element, etc. in relation
to one embodiment should not be construed as being limited to applications
only within said
embodiment. In addition, reference to a specific benefit, advantage, problem,
solution, method
of use, etc. in relation to one embodiment should not be construed as being
limited to
applications only within said embodiment.
[0032] The headings used herein are for organizational purposes only and
are not meant to be
used to limit the scope of the description or the claims. To facilitate
understanding, like
reference numerals have been used, where possible, to designate like elements
common to the
figures.
[0033] The present invention relates to methods for forming noise absorbing
barrier walls and
forms used in producing such walls. The noise absorbing barrier walls are
typically placed along
one or opposing sides of a roadway, such as a highway, freeway, city road or
the like, and are
used to decrease or absorb noise generated by traffic moving along the
roadway. In alternative
uses, the noise absorbing barrier walls can also be placed at other locations
where it is desired to
decrease noise pollution, such as around or along raceways, outdoor stadiums,
or other event
centers. Other uses are also applicable.
[0034] Depicted in Figures 1 and 2 is one embodiment of an inventive form
10 for use in
forming a barrier wall and, more specifically, a noise absorbing barrier wall.
In general, form 10
comprises a mold 12 in which the barrier wall is formed and a stand 14 on
which mold 12 is
supported. As discussed below, stand 14 is configured so that mold 12 can be
rotated between a
vertical orientation and a horizontal orientation. An expansion cylinder 16,
such as a hydraulic
or pneumatic cylinder, or other mechanisms, can be used to selectively move
mold 12 between
the vertical orientation and the horizontal orientation.
[0035] Depicted in Figure 3, mold 12 generally has a box shaped
configuration that includes a
front wall 20 and an opposing rear wall 22 that each extend between an upper
end 24 and an
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opposing lower end 26 and that also extend between a first side end 28 and an
opposing second
side end 30. Mold 12 further includes a top wall 32 extending between walls 20
and 22 at upper
end 24; a bottom wall 34 extending between walls 20 and 22 at lower end 26; a
first side wall 36
extending between walls 20 and 22 at first end 28; and a second side wall 38
extending between
walls 20 and 22 at second end 30.
[00361 As more clearly depicted in Figure 4, the depicted embodiment of
mold 12 comprises
a mold body 40 that is comprised of a plurality of panels secured together. In
turn, various
supports can be secured to the panels of mold body 40. More specifically, as
depicted in Figure
5, mold body 40 also has a box shaped configuration that includes upper end 24
and an opposing
lower end 26 and also first side end 28 and opposing second side end 30. Mold
body 40 includes
a front panel 42 and an opposing rear panel 44. Mold body 40 further includes
a top panel 46
extending between panels 42 and 44 at upper end 24; a bottom panel 48
extending between
panels 42 and 44 at lower end 26; a first side panel 50 extending between
panels 42 and 44 at
first end 28; and a second side panel 52 extending between panels 42 and 44 at
second end 30.
[0037] Mold body 40 bounds a compartment 60 in which the barrier wall is
formed. Front
panel 42 has an interior surface 62 that partially bounds compartment 60, an
exterior surface 64,
and an encircling perimeter edge 66. Likewise, rear panel 44 has an interior
surface 68 that
partially bounds compartment 60, an exterior surface 70, and an encircling
perimeter edge 72.
Front panel 42 and rear panel 44 are each depicted as having an elongated
rectangular
configuration. However, other configurations, such as square, can also be
used.
[0038] Top panel 46 has an interior surface 74 that partially bounds
compartment 60, an
exterior surface 76, an encircling perimeter edge 78 and a lip 80 that
outwardly projects from
perimeter edge 78. Bottom panel 48 has an interior surface 82 that partially
bounds compartment
60, an exterior surface 84, an encircling perimeter edge 86 and a lip 88 that
outwardly projects
from perimeter edge 86. First side panel 50 has an interior surface 90 that
partially bounds
compartment 60, an exterior surface 92, and lips 94 and 96 that outwardly
projecting from
opposing side edges thereof. Finally, second side panel 52 has an interior
surface 98 that
partially bounds compartment 60, an exterior surface 100, and lips 102 and 104
that outwardly
projecting from opposing side edges thereof.
[0039] During assembly, bottom panel 48, first side panel 50 and second
side panel 52 are
secured to rear panel 44 along perimeter edge 72 at lower end 26, first end 28
and second end 30,
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respectively, so that panels 48, 50 and 52 connect together and outwardly
project from interior
surface 68. Panels 48, 50 and 52 can be permanently or removably attached to
rear panel 44.
For example, panels 48, 50 and 52 can be welded to rear panel 44 or fasteners,
such as bolts,
screws, rivets, or other fasteners, can be passed through lips 88, 96, and 104
and through rear
panel 44 for securing. Other attachment techniques can also be used.
[0040] Because panels 42, 44, 46, 48, 50, and 52 form at least portions of
walls 20, 22, 24, 26,
28, and 30, respectively, it is submitted that reference to one or more panels
42, 44, 46, 48, 50,
and 52 herein also constitutes disclosure as reference to one or more
corresponding walls 20, 22,
24, 26, 28, and 30 and vice versa, unless clearly indicated otherwise by the
context of the
disclosure. For example, reference to removal, movement or attachment of one
or more panels
also constitutes disclosure of removal, movement or attachment of one or more
corresponding
walls and vice versa. Likewise, reference to an interior surface of one or
more panels also
constitutes disclosure of reference to an interior surface of the one or more
corresponding walls
and vice versa.
[0041] Top panel 46 is also attached to rear panel 44 along perimeter edge
72 at upper end 24.
However, top panel 46 is positioned to be selectively removable or movable so
that compartment
60 can be accessed. For example, in the depicted embodiment as shown in Figure
3, a plurality
of spaced apart hinges 108A, 108B and 108C are used to hingedly secure an edge
of top panel 46
along upper end 24 of rear panel 44. Accordingly, top panel 46 can be
selectively rotated
between a first or closed position as shown in Figures 3 and 7 and a second or
open position as
shown in Figures 5 and 9. In the closed position, top panel 46 can be secured
in place by
fasteners 110A and 110B (Figure 5) passing through an opening in the end of
side panels 50 and
52 and threading into openings 112 formed on lip 80 of top panel 46.
Alternatively, fasteners
110A and 110B could pass through openings 112 and then be threaded into nuts.
Other
removable fastening techniques can also be used. To move top panel 46 to the
open position,
fasteners 110A and 11013 are removed and top panel 46 is manually rotated
about hinges 108
into the open position. When top panel 46 is in the open position, an access
opening 113 (Figure
9) is formed that communicates with compartment 60. In an alternative
embodiment, top panel
46 need not be hingedly connected to rear panel 44 but can simply be removably
connected to
rear panel 44. For example, top panel 46 can be removably attached to rear
panel 44 and side
panels 50 and 52 by removable fasteners, such as bolts, screws, clamps or the
like. As such, top
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panel 46 can be completely removed from panels 44, 50 and 52 to expose access
opening 113
and can be selectively reattached to cove access opening 113.
[0042] The assembled rear panel 44, top panel 46, bottom panel 48 and side
panels 50 and 52
combined to form a base 114 of mold body 40. As used herein, base 114 can also
reference the
assembled rear wall 22, top wall 32, bottom wall 34, first side wall 36 and
second side wall 38 of
mold 12 as shown in Figure 7. Base 114 is configured so that front panel
42/front wall 20 can be
selectively attached and removed from base 114. For example, openings 118
extends through
perimeter edge 66 of front panel 42 and match with openings 120 formed lips
88, 94, and 102 on
panels 48, 50, and 52, respectively. Accordingly, by position front panel
42/front wall 20 on
panels 48, 50, and 52, fasteners 122 (Figure 2) can be passed through or
threaded into openings
118 and 120 for removably securing front panel 42/front wall 20 to base 114 of
mold 12. It is
also appreciated that nuts can be used with fasteners 112 for securing in
place. Other
conventional fasteners and fastening techniques can also be used.
[00431 By using fasteners 112, front panel 42 can be selectively moved to a
first or closed
position, as depicted in Figures 2 and 6, where front panel 42 is secured to
base 114 of mold
body 40 and assists in enclosing compartment 60. Front panel 42 can also be
selectively moved
to a second or open position, as depicted in Figure 7, where front panel 42 is
removed from base
114 of mold body 40 so that an access opening 124 to compartment 60 is
exposed. Access
opening 124 is covered by front panel 42 when front panel 42 is in the first
or closed position. In
contrast to being fully removable from base 114 of mold body 40, front panel
42 could also be
hingedly attached to base 114, such as along bottom panel 48. In this
configuration, front panel
42 can still be selectively moved between the open and closed positions
relative to base 114.
[0044] The panels of mold body 40 are typically formed of a metal plate
such as steel or
aluminum. However, in other embodiments, the panels can be made of wood,
plastic fiberglass,
composite or other materials. To increase the structural stability of the
panels and prevent
unwanted bending, support members can be secured to front panel 42 and rear
panel 44.
Specifically, as depicted in Figures 3 and 4, a plurality of elongated
supports 130A-130G are
secured to exterior surface 70 of rear panel 44 at spaced apart locations so
as to extend between
upper end 24 and lower end 26. Supports 130 can be secured to rear panel 44 by
welding,
adhesive, or using fasteners such as screw or bolts. Other securing techniques
can also be used.
Supports 130 are typically in the form of channel beams or I-beams that are
formed of metal.
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However, other shaped beams can be used and they can be made of other material
such was
wood, plastic, fiberglass, composite or the like. The number of supports 130
used depends on
the size of rear panel 44. Typically, however, the number of supports 130 used
is at least or not
to exceed 2, 3, 4, 6, 8, 10 or is in a range between any two of the foregoing.
Rear panel 44 and
supports 130 can combine to form rear wall 22, previously discussed.
[0045] By using the combination of rear panel 44 and supports 130, rear
panel 44 can be
made thinner, thereby decreasing cost and weight, yet the overall rear wall 22
can still have the
desired strength and stiffness. In other embodiments, however, rear wall 22
can be formed by
eliminating supports 130 and simply increasing the thickness of rear panel 44.
In still other
embodiments, rear wall 22 can be formed by forming rear panel 44 so that ribs
or other support
structures are integrally formed therein so as to increase the strength and
stiffness of rear panel
44.
[0046] To further increase the strength and stiffness of rear wall 22/ rear
panel 44, rear wall
22 can also include one or more further supports 132 secured to rear panel 44
and extending
between first end 28 and opposing second end 30 so as to be positioned over
supports 130A-G.
In the depicted embodiment, a support 132A centrally extends over supports 130
while a support
132B extends over supports 130 at upper end 24. Supports 132 can have the same
alternative
configurations as supports 130. Other numbers and orientations of supports 132
can also be
used.
[0047] The configuration of front wall 20 can be the same as and have the
same alternatives
as rear wall 22. As such, all of the above discussion of rear wall 22 is also
applicable to front
wall 20. For example, as with rear wall 22, front wall 20 can comprise front
panel 42 having a
plurality of supports 134A-G (which correspond to supports 130A-G) secured to
exterior surface
74 at spaced apart locations so as to extend between upper end 24 and lower
end 26. Again, the
attachment method, number, configuration, and purpose of supports 134A-G can
be the same as
discussed above with regard to supports 130A-G. Likewise, to further increase
the strength and
stiffness of front wall 20, one or more further support 136 can be secured to
front panel 42
extending between first end 28 and opposing second end 30 so as to be
positioned over supports
134A-G. In the depicted embodiment, a support 136A centrally extends over
supports 134 while
a support 136B extends over supports 134 at upper end 24. Supports 136 can
have the same
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alternative configurations as supports 134. Other numbers and orientations of
supports 136 can
also be used.
[0048] With reference to Figure 3, a brace 150A is centrally mounted on the
exterior surface
of first sidewall 36. As will be discussed below in greater detail, outwardly
projecting from brace
150A is an axle 152A. In this embodiment, axle 152A is positioned so as to be
centrally
disposed relative to both the height and width of first sidewall 36. With
reference to Figure 2 a
corresponding brace 150B is also secured on the exterior surface of second
sidewall 38 with an
axle 152B outwardly projecting therefrom. Axle 152B is also positioned so as
to be centrally
disposed relative to both the height and width of second sidewall 38. As a
result, axles 152A and
152B are disposed along a common axis 154.
[0049] In general, the size of mold 12 is dependent upon the size of
barrier wall to be
manufactured. With reference to Figure 7, compartment 60 has a height H
extending between
the interior surfaces of top panel 46 and bottom panel 48; a length L
extending between the
interior surfaces of side panels 50 and 52; and a width W extending between
the interior surfaces
of front panel 42 and rear panel 44. In some embodiments, the height H is at
least .75, 1, 1.2,
1.5, 1.8, 2, 2.5, 3, or 4 meters or is in a range between any two of the
foregoing. The length L is
at least 1, 1.5. 2, 2.5, 3, 3.5, 4, 5 or 6 meters or is in a range between any
two of the foregoing.
The width W is typically less than 0.7, 0.5, 0.3, 0.2, 0.1 or 0.07 meters or
is in a range between
any two of the foregoing. In one embodiment, the height H and the length L are
greater than the
width W by a factor of at least 2, 3, 4, 6, 8, 10, 12, 15, or 20. In another
embodiment, the length
L is greater than the width W by a factor of at least 1.2, 1.5, 1.75, 2, 2.5
or 3. Other ratios can
also be used. In each of the foregoing examples, the referenced height H,
length L, and width W
can correspond a maximum or a minimum height H, length L or width W.
Compartment 60
typically has a volume of at least or less than 0.2, 0.3, 0.5, 0.6, 0.8, 1,
1.2, 1.5, 1.8, 2, 2.5, 3, or 4
cubic meters (m3) or can be in a range between any two of the foregoing.
[0050] In one embodiment, compartment 60 can be a cuboid so that all
opposing surfaces are
parallel. However, in alternative embodiments, the interior surfaces of front
panel 42 and rear
panel 44 and/or the interior surfaces of top panel 48 and bottom panel 50,
and/or the interior
surfaces of side panel 50 and side panel 52 can be disposed in converging or
diverging planes or
one of the opposing panels can be angled relative to the other. The resulting
barrier wall can
then then having corresponding opposing surfaces.
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[0051] In another alternative embodiment, it is appreciated that each of
some of the interior
surfaces of mold body 40 bounding compartment 60 need not be flat but can be
contoured with a
design or texture. This can be accomplished by forming a desired contour of a
design or texture
directly on the interior surface of each panel or, alternatively a liner can
be attached to one or
more of the interior surfaces of each of the panels, each liner having the
desired contour of a
design or texture formed thereon. For example, as depicted in Figure 7, a
liner 140A can be
secured to or positioned against interior surface 68 of rear panel 44 while a
liner 140B can be
secured to or positioned against interior surface 62 of front panel 42. The
contours on the
interior surface of the panels or liners could be in the shape of rocks,
blocks, bricks, columns, or
other shapes that are recessed into or outwardly project from the panels or
liners. As discussed
below in more detail, these contours of design or texture are transferred to
the exterior surface of
the barrier wall during the manufacturing process. The contour can be the same
or different for
each panel.
[0052] As shown in Figures 3, 3A and 7, in one embodiment mold 12 can
comprise extractors
168A and 168B mounted on the opposing ends of rear wall 22/rear panel 44 at
lower end 26 that
are used to help remove the formed barrier wall from compart 60. As depicted
in Figure 3A,
extractor 168A generally comprises a base 169 having a threaded opening and a
pusher 170 that
is threaded into the threaded opening. More specifically, base 169 is depicted
as comprising a
support 171, such as in the form of a channel beam or I-beam, secured to rear
panel 44 at lower
end 26 and first end 28. Support 171 can be secured such as by welding or the
use of fasteners.
An opening 172 passes through support 170. A nut 173 having a threaded opening
174 is
secured to support 170, such as by welding, so that threaded opening 174 is
aligned with opening
172. In an alternative embedment, nut 173 could be eliminated and opening 172
could be
threaded.
[0053] As depicted in Figure 7, pusher 170 comprises a threaded shaft 175
having a free first
end and an opposing second end having a radially outwardly projecting plate
176 mounted
thereat. Plate 176 is typically mounted on shaft 175 so that shaft 175 can
freely rotate
independent plate 176. As also depicted in Figure 7, a hole 177 passes through
rear panel 44 in
alignment with opening 172 on support 170 (Figure 3A). Where liner 140A is
disposed on
interior surface 69 of rear panel 44, hole 177 also passes through liner 140A.
12
CA 3002249 2018-04-25
[0054] During assembly, the first end of threaded shaft 177 is passed
through hole 177 of
liner 140A and rear panel 44, through opening 172 and threaded into threaded
opening 174 of
nut 173. Threaded shaft 175 is advanced until plate 176 is flush against liner
140A or flush
against rear panel 44 where liner 140A is not used. As depicted in Figure 3A,
nuts 178A and
178B are then threaded onto the first end of threaded shaft 175 and then
tightened together so
that rotation of nut 178B causes rotation of threaded shaft 175.
[0055] In this assembled condition, as discussed below in greater detail,
once the barrier wall
is formed and ready to be removed from mold 12, front wall 20 is removed from
mold 12.
Pusher 170 can then be advanced into compartment 60 by using a wrench or other
tool to rotate
nut 178B so as to rotate threaded shaft 175. As threaded shaft 175 is rotated,
threaded shaft 175
advances into compartment 60. In turn, plate 176 pushes against the formed
barrier wall and
assists to both separate the barrier wall from liner 140A and to push the
barrier wall out of
compartment 60. Extractor 168B has the same elements and is used in the same
way as extractor
168A. As such, like elements between extractor 168A and 168B are identified by
like reference
characters. The only difference is that extractor 168B is located on lower end
26 of rear panel 44
at second end 30.
[00561 In some embodiments, it is appreciated that mold 12 can be formed so
that
compartment 60 has a uniform and constant width W over the entire length L and
height H. In
other embodiments, although the width W may be constant over a majority of the
length L or
height H, the width W may taper, expand or have other configurations adjacent
to panels 46, 48,
50 and/or 52. In still other embodiments, the width W, length L and/or height
H can each vary
or be constant, as desired.
[0057] Turning to Figure 3, stand 14 comprises a base 142 and a pair of
spaced apart risers
144A and 144B upstanding therefrom. Risers 144A and 144B each have a lower end
146 and an
opposing upper end 148. Disposed at upper end 148 of each riser 144A and 144B
is a shaft
support 156A and 156B, respectively, that is configured to receive and support
axles 152A and
152B, respectively, so that axles 152 can freely rotate therein. Shaft support
156 can comprise
any structure or surface that can receive and retain axles 152 and permit the
rotation of axles 152.
For example, shaft supports 156 can comprise tubular members, U-shaped
members, or other
structures. In one embodiment, each shaft support 156 comprises a tubular
bearing housing 157
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CA 3002249 2018-04-25
in which an annular bearing is disposed. Axles 152 are received within bearing
housing 157 so
as to ride on the bearings during rotation. However, it is not required that a
bearing be used.
[0058] Base 142 includes a support foot 158A and 158B disposed at lower end
146 of risers
144A and 144B, respectively, for resting on a ground surface. A pair of spaced
apart, elongated
braces 160A and 160B extend between feet 158A and 158B. In other embodiment, a
single
brace or three of more braces can be used.
[0059] During assembly, axles 152 of mold 12 are received within shaft
supports 156 so that
mold 12 is fully supported on risers 144 of stand 14. In this position, mold
12 is also rotatable
relative to stand 14 by axles 152 rotating within shaft supports 156. Mold 12
can typically be
rotated over an angle of at least 900 between a first or horizontal
orientation as shown in Figures
6 and a second or vertical orientation as shown in Figures 1 and 2. That is,
mold 12 can include
an axis 164 that passes between top wall 32 and bottom wall 34. Axis 164 can
be disposed to
pass centrally through compartment 60 (Figure 7) relative to both length L and
width W. In
Figures 1 and 2, with mold 12 in the vertical orientation, axis 164 is
vertically orientated while in
Figure 6 with mold in the horizontal orientation, axis 164 is horizontally
disposed. In some
embodiments, however, it is not necessary that that axis 164 be exactly
vertically and
horizontally disposed. For example, in the vertical orientation, axis 164
could be in a range of
+/- 15 , 100, 50, or 3 relative to vertical while in the horizontal
orientation, axis 164 could be in
a range of +/- 15 , 10 , 5 , or 3 relative to horizontal. In some embodiment,
it is also
appreciated that mold can rotate over an angle of at least or less than 1100,
100 , 95 , 90 , 850
,
80 , 70 or in a range between any two of the foregoing. In the depicted
embodiment, mold 12
has only a single axis of rotation. That is, form 10 is configured so that
mold 12 can only rotate
about a single axis.
[0060] Because axles 152 are centrally or symmetrically located on side
walls 36 and 38
relative to the height and width of mold 12, mold 12 is centrally balanced on
risers 144, thereby
making it easier to rotate mold 12 between the vertical and horizontal
orientations. However, it
is also envisioned that axles 152 could be asymmetrically positioned on side
walls 36 and 36
such as by being positioned toward or directly on front wall 20 or rear wall
22 and/or positioned
toward or directly on top wall 32 or bottom wall 34. It is also appreciated
that axles 152 and
shaft supports 156 can be switched. That is, shaft supports 156 can be secured
to mold 12 while
axles 152 can be secured to risers 144.
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[0061] As depicted in Figures 3 and 6, rests 166A and 166B can be secured
to base 142 at
opposing ends of stand 14 so as to upstand therefrom. Rests 166 are configured
so that when
mold 12 is in the horizontal orientation, upper end 24 of mold is supported by
sitting on top of
rests 166. Rest 166 can thus be used to both support mold 12, i.e., carry part
of the weight
thereof, and ensure that mold 12 is rotated to the desired orientation. That
is, mold 12 is rotated
until mold 12 comes to rest on rests 166. In an alternative embodiment, rests
166 could be
secured to upper end 24 of mold 12 at the opposing ends thereof. During use,
rests 166 would
then come to rest on base 142 and/or on a ground surface when mold 12 is moved
to the
horizontal orientation. Although two rests are shown, the system can be formed
with a single
rest 166 located at one end or more centrally, or could be formed with three
or more spaced apart
rests 166. In other embodiments, rests 166 are not required.
[0062] One embodiment of the present invention includes means for
selectively rotating mold
12 between the first/horizontal orientation and the second/vertical
orientation. Such means can
be coupled to mold 12 and/or stand 14 or extend therebetween. By way of
example and not by
limitation, depicted in Figure 1 is expansion cylinder 16, which can be a
pneumatic or hydraulic
cylinder. Expansion cylinder 16 has a first end 180 that is hingedly coupled
with stand 14 and an
opposing second end 182 that is hingedly coupled to mold 12. More
specifically, with reference
to Figure 3, expansion cylinder 16 includes a cylinder body 184 having first
end 180 and a piston
rod 186 that is slidably received within cylinder body 184 and includes second
end 182. A pair
of rails 188A and 188B are centrally mounted on base 142 of stand 14 and bound
a channel 190
therebetween. Channel 190 is sized so that at least portion of expansion
cylinder 16, and in some
embodiments all of expansion cylinder 16, can be received within channel 190.
First end 180 is
received within channel 190 while a bolt 192 is secured to rails 188 and
passes through first end
180. First end 180 pivots about bolt 192. A pair of arms 194A and 194B project
from rear wall
22 of mold 12 at or toward lower end 26, i.e., below axis 154 (Figure 2).
Second end 182 is
received between arms 194 while a bolt 196 (Figure 1) is secured to arms 194
and passes through
second end 182. Second end 182 pivots about bolt 196.
[0063] An actuator 200 is provided with a pair of fluid lines 202A and 202B
that extend from
actuator 200 to the opposing ends of cylinder body 184. Actuator 200 can
comprise a pump for
delivering hydraulic fluid in and out of the opposing ends of cylinder body
184 or a compressor
for delivering compressed gas into and out of the opposing ends of cylinder
body 184. As is
CA 3002249 2018-04-25
known in the art, delivering hydraulic fluid or compressed gas into and out of
cylinder body 184
selectively moves piston rod 184 into and out of cylinder body 184.
Accordingly, by selectively
operating actuator 200, expansion cylinder 16 can be moved between a collapsed
position and an
expanded position. As expansion cylinder 16 is moved to the collapsed
position, as shown in
Figures 1-3, expansion cylinder 16 causes mold 12 to rotate into the
second/vertical orientation.
In turn, as expansion cylinder 16 is moved to the expanded position, as shown
in Figures 6 and 7,
expansion cylinder 16 causes mold 12 to rotate into the first/horizontal
orientation. Actuator 200
and expansion cylinder 16 can also be used for securely holding mold 12 in the
second/vertical
orientation and the first/horizontal orientation. In addition, actuator 200
and expansion cylinder
16 can also be used for securely holding mold 12 at any desired angle of
orientation between the
second/vertical orientation and the first/horizontal orientation.
[0064] Although the depicted embodiment shows the use of a single expansion
cylinder 16
located centrally on mold 12 and base 142, in other embodiments, expansion
cylinder 16 can be
located at or toward first end 28 or second end 30 or two or more spaced apart
expansion
cylinders 16 can be used. Furthermore, in contrast to second end 182 being
connected at or
toward lower end 26 of mold 12, second end 182 could be connected at or toward
upper end 24
of mold 12, i.e., above axis 154 (Figure 2), and still facilitate rotation of
mold 12.
[0065] In other embodiments of the means for selectively rotating mold 12
between the first/
horizontal orientation and the second/vertical orientation, expansion cylinder
16 could be
replaced with other mechanical devices that can be used for rotating mold 12.
For example,
cable, chain, or gear assemblies operating with one or more electrical motors
can be used to
selectively rotate mold 12. Other conventional techniques can also be used.
[0066] In other embodiments of the present invention, expansion cylinder 16
can be
eliminated and mold 12 can be rotated manually, such as through the use of a
lever.
Furthermore, an apparatus that is not connected to mold 12 or stand 14, such
as a backhoe, can
be used to rotate mold 12.
[0067] During use, mold 12 is initially rotated to the first/horizontal
orientation, as depicted in
Figure 7, such as through the use of expansion cylinder 16. Mold 12 is
securely held in the
first/horizontal orientation, such as through expansion cylinder 16 or by
using a separate locking
feature. Either prior to or after mold 12 is rotated to the first/horizontal
orientation, front wall
20/front panel 42 is removed from or rotated on base 114 of mold 12 so that
access opening 124
16
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to compartment 60 is openly exposed. In this position, panels 46, 48, 50 and
52 are upstanding
from rear panel 44 and combine to form a sidewall 202 that encircles
compartment 60.
Expressed in other terms, top wall 32, bottom wall 34, first sidewall 36 and
second side wall 38
are upstanding from rear wall 22 and likewise combine to form a sidewall 202
that encircles
compartment 60.
[0068] Next, as depicted in Figure 8, a noise absorbing material 204 is
deposited within
compartment 60 so as to rest on interior surface 68 of rear panel 44/rear wall
22. Noise
absorbing material is a material that has enhanced sound dampening or noise
absorbing qualities.
In one embodiment, noise absorbing material 204 can comprise a curable
material that is mixed
together, placed and then left to cure. Most commonly, noise absorbing
material 204 comprises
a noise absorbing component that is mixed with hydraulic cement and water. The
noise
absorbing component will commonly comprise natural rubber, synthetic rubber,
wood, or
polymeric foam that is ground, shred or otherwise formed into small pieces
typically having an
average diameter that is less than 4 cm, 3 cm, 2 cm, 1 cm, .5 cm, .2 cm or is
in a range between
any two of the foregoing. Other soft or resiliently compressible materials
having noise absorbing
properties can also be used as the noise absorbing components. Combinations of
the foregoing
materials can also be used. In addition to the noise absorbing component,
hydraulic cement and
water, noise absorbing material 204 can commonly comprise lightweight
aggregate. Lightweight
aggregate includes aggregate meeting the requirements of ASTM C 330 with bulk
density less
than 70 lb/ft' (1120 kg/m3) for fine aggregate and less than 55 lb/ft' (880
kg/m3) for coarse
aggregate. Lightweight aggregate can comprise aggregates comprised of blast-
furnace slag, clay,
fly ash, shale, or slate that are prepared by expanding, pelletizing, or
sintering, and can comprise
aggregates prepared by processing natural materials such as pumice, scoria or
tuff. Noise
absorbing material 204 can also comprise other additives such as an air-
entraining admixture
(AEA). Other additives can also be added.
[0069] Noise absorbing material 204 typically has a very low slump or no
slump when first
formed and is not self-leveling. During the formation of the barrier wall,
noise absorbing
material 204 is deposited on interior surface 68 of rear panel 44/rear wall 22
and then spread to
form layer 206. Commonly, noise absorbing material 204 is tamped flat against
liner 140A or
interior surface 68 to form layer 206. By tamping noise absorbing material 204
against liner 140,
17
CA 3002249 2018-04-25
the outside face of layer 206 contours to or imprints the texture of liner
140A. Tamping also
increases the density and structural strength of layer 206.
[0070] Layer 206 can extend to encircling sidewall 202 so as to completely
cover interior
surface 68 of rear panel 44/rear wall 22 within compartment 60. However, in
other
embodiments, layer 206 need not cover all of rear panel 44 and can be spaced
apart from
sidewall 202 at some or all locations. For example, partitions can be disposed
on rear panel 44
for controlling the layout of noise absorbing material 204. Furthermore,
depending on the
configuration of interior surface 68 of rear panel 44, layer 206 can have a
uniform thickness or a
variable thickness. For example, if contours of designs or texture are formed
on interior surface
68 of rear panel 44 or on the interior surface of liner 140 (Figure 7)
positioned on interior surface
68 of rear panel 44, layer 206 can have a corresponding variable thickness.
Typically, layer 206
will have a thickness T1 that is at least or less than 1, 3, 5, 7, 10, 15, 20,
30, or 40 cm or in a
range between any two of the foregoing. The above values for thickness Ti can
be maximum
values or minimum values for the thickness T1. Other values can also be used.
[0071] After noise absorbing material 204 is properly positioned to form
layer 206, a
cementitious material 208 is placed on top of layer 206. Cementitious material
208 comprises
hydraulic cement, aggregate and water. Other fillers and/or additives, such as
fibers, hardener,
plasticizer, air-entraining admixture (AEA), color, or combinations of the
forgoing can be added.
In one embodiment, cementitious material 208 comprises a self-consolidating
concrete (SCC).
Self-consolidating concrete is a highly flowable, non-segregating concrete
that spreads to fill a
space without any mechanical vibration. Even if not a self-consolidating
concrete, cementitious
material 208, when first mixed, is typically designed to be highly flowable so
as to be self-
leveling.
[0072] Noise absorbing material 204 typically has a relatively low strength
and thus is either
not independently self-supporting as a wall structure or will fail under
unacceptably low loads or
forces. Cementitious material 208, when hardened, has a higher compressive
strength, tensile
strength, and/or density than noise absorbing material 204 when hardened but
has lower noise
absorbing properties than noise absorbing material 204. In one embodiment,
cementitious
material 208, when hardened, can have a compressive strength, tensile
strength, and/or density
that is at least 1.5, 2, 3, 4, 5, 6 or 7 time greater than that of noise
absorbing material 204 when
hardened. Accordingly, cementitious material 208 acts as a supporting
structure for noise
18
CA 3002249 2018-04-25
absorbing material 204 so that noise absorbing material 204 can be held and
supported in the
form of a wall. One of the benefits of having both noise absorbing material
204 and
cementitious material 208 include a hydraulic cement is that the materials
easily bond together
during the curing stage so that cementitious material 208 can effectively
support noise absorbing
material 204. Noise absorbing material 204, when hardened, is typically at
least 1.5, 2, 2.5, 3, 4,
or 5 times more effective at absorbing noise than cementitious material 208,
when hardened.
[0073] During application, cementitious material 208 is typically deposited
as a layer 210
formed on top of layer 206. Again, this is typically accomplished by simply
pouring
cementitious material 208 which is highly flowable so that it self levels into
layer 210. Layer
210 typically extends to encircling sidewall 202 so as to completely cover and
bond to layer 206.
Where portions of rear panel 44 are not covered by layer 206, portions of
layer 210 could extend
to rear panel 44 or liner 140 disposed thereon. As such, layer 210 can have a
uniform thickness
or variable thickness. Typically, layer 210 will have a thickness T2 that is
at least or less than 3,
5, 7, 10, 15, 20, 30, or 40 cm or in a range between any two of the foregoing.
The above values
for thickness T2 can be maximum values for minimum values. Other values can
also be used.
Commonly, T2 will have a thickness that is at least 1 cm, 2 cm 3 cm, 5 cm, 7cm
or 10 cm greater
than the thickness of Ti. To further increase the strength of layer 210,
reinforcing 211, such as
rebar, mesh, wire or the like, can be embedded within layer 210 using
conventional techniques.
[0074] With reference to Figure 8, layer 210 is formed so that a gap 214
will be formed
between a top surface 212 of layer 210 and interior surface 62 of front panel
42/front wall 20
(Figure 7) when front panel 42/front wall 20 is secured back onto base 114 of
mold 12. The
formation of gap 214 achieves a couple of benefits. Initially, the amount of
cementitious
material 208 needed to fill the unoccupied space of compartment 60 can be
large and, due to
variance in noise absorbing material 204, difficult to measure. Accordingly,
if attempts are made
to fill compartment 60 exactly to the top of panels 46, 48, 50 and 52, i.e.,
encircling sidewall
202, the process could be very slow and labor intensive by incrementally
adding material 208
until the exact volume is reached. Furthermore, if too much cementitious
material 208 is added,
cementitious material 208 can overflow mold 12 which is both messy and
wasteful.
[0075] The problem is compounded when it is desired to form a design or
texture on top
surface 212 of layer 210 by using liner 140B (Figure 7) or by forming a
contour of design or
texture on interior surface 64 of front panel 42/front wall 20. That is, when
using liner 140B or
19
CA 3002249 2018-04-25
design or texture on interior surface 64 of front panel 42/front wall 20, it
is impossible to know
how much cementitious material 208 to add to compartment 60 since part of
compartment 60
will be occupied by liner 140B or the design or texture on front panel 42. If
too much
cementitious material 208 is added, it can be impossible to attach front panel
42/front wall 20.
As such, front panel 42/front wall 20 would then need to be moved and part of
cementitious
material 208 removed from compartment 60 until front panel 42/front wall 20
can be attached.
In contrast, by using gap 214, which need not be a defined dimension,
compartment 60 can be
quickly and easily filled with cementitious material 208 without risk of
overfilling, thereby
increasing production time and minimizing labor and waste. Furthermore, as
discussed below in
more detail, even when using gap 214, transferring designs or texture from
front panel 42 or liner
140B to top surface 212 of layer 210 is easily achieved.
[0076] Gap 214 is typically less than or greater than 0.5, 1, 1.5, 2, 3, 4,
or 5 cm or is in a
range between any two of the foregoing. Other dimensions can also be used.
Because top
surface 212 of layer 210 can be at least slightly irregular, the above values
for gap 214 can be a
maximum value or a minimum value. Gap 214 is typically formed by forming top
surface 212 of
layer 210 the distance of gap 214 below a top perimeter edge 222 of encircling
sidewall 202 as
shown in Figure 8. Alternatively or in combination, a spacer 216, as shown in
Figure 7, can be
placed between perimeter edge 222 of encircling sidewall 202 and front panel
42 so that gap 214
is formed even if cementitious material 208 is filled up to perimeter edge 222
of encircling
sidewall 202. Spacer 214 can be independent of encircling sidewall 202 and
front panel 42 or
can be integrally formed with or otherwise secured to interior surface 62 of
front panel 42 around
the perimeter edge thereof.
[0077] Once layer 210 of cementitious material 208 is formed with gap 214,
front wall
20/front panel 42 is secured to base 114 so as to cover access opening 124 and
enclose
compartment 60. Mold 12 is then rotated, such as through the use of expansion
cylinder 16, to
the second/vertical orientation as shown in Figure 9. Top wall 32 is then
moved so that access
opening 113 to compartment 60 is exposed. As previously discussed, top wall 32
can be moved
by hingedly rotating top wall 32, by completely removing top wall 32, or by
otherwise moving
top wall 32 to expose access opening 113. One of the unique benefits of the
present invention is
that as mold 12 is rotated from the first/horizontal orientation to the
second/vertical orientation,
cementitious material 208 will automatically downwardly flow away from top
wall 32 and
,CA 3002249 2018-04-25
outwardly flow against interior surface 62 of front panel 42/front wall 20 so
as to fill gap 214
without any use of mechanical vibration. Again, this is achieved in part
because cementitious
material 208 is formed as a highly flowable material. Thus, where liner 140B
(Figure 7) is used,
cementitious material 208 will flow against the interior surface of line 140B
and conform to the
design or texture formed thereon. The same is true if a design or texture is
formed directly on
the interior surface of front panel 42/front wall 20. Accordingly, in contrast
to the prior state of
the art, the present invention is able to produce a noise absorbing wall where
the outside face of
the wall is able to achieve a formed texture having deep and realistic
features as opposed to
merely a shallow stamped texture. As such, the inventive noise absorbing walls
have a
significantly improved texture and appearance on the face relative to the
prior art.
[0078] It is noted that gap 214 is typically made relatively small so that
sufficient
cementitious material 208 is within compartment 60 to support layer 206
against rear panel 44 as
mold 12 is moved from the first/horizontal orientation to the second/vertical
orientation. That is,
cementitious material 208 helps to prevent the collapse of layer 206.
[0079] Because noise absorbing material 204 is stiff and compacted, there
will typically be no
slumping or movement of layer 206 as mold 12 is rotated from the horizontal
position to the
vertical position. However, because of the down and outward flow of
cementitious material 208
into gap 214, a new gap 220 (Figure 9) is now formed between the new top
surface of
cementitious material 208 and interior surface 74 of top panel 46/top wall 32
when top panel
46/top wall 32 is in the closed position. However, gap 220 can be easily
filled by simply pouring
more cementitious material 208 into the area of gap 220 through expose access
opening 113 as
shown in Figure 10. If any downward slumping of layer 206 occurs, that gap can
also be filled
with cementitious material 208.
[0080] Prior to or after filling gap 220, lifting anchors 234A and 234B
(Figure 10) are
inserted through access opening 113 into uncured layer 210 of cementitious
material 208 toward
the opposing ends thereof. Each lifting anchor 234 comprises an elongated body
236 that
extends down into layer 210 so that lifting anchors 234 are securely held by
layer 210 when layer
210 has cured. Lifting anchors 234 also comprise a coupling head 238 that is
attached to body
236 and can be easily coupled to for picking up and moving the resulting
barrier wall. For
example, coupling head 238 typically comprises a ring, loop, hook or other
structure having an
opening that that can be engaged by a hook mounted on a lift, such as a crane.
One of the
21
CA 3002249 2018-04-25
benefits of the present invention is that because top wall 32 is moved to the
open position prior to
the curing of layer 210, it is easy and simple to attach lifting anchors 234.
Once layer 210 is
complete and lifting anchors 234 are attached, cementitious material 208 and
noise absorbing
material 204 are allowed harden and bond together while mold 12 remains in the
second/vertical
orientation.
[0081] Because mold 12 can be left in the second/vertical orientation during
hardening/curing, mold 12 occupies less lateral space, thereby enabling more
barriers walls to
simultaneously be formed. During the hardening/curing process, top wall 32/top
panel 46 can be
left open as shown in Figure 10. Once cementitious material 208 and noise
absorbing material
204 sufficiently hardened/cured to form a self-supporting noise absorbing
barrier wall 226, mold
12 can be opened and barrier wall 226 removed, as shown in Figure 11. Barrier
wall 226 is
typically removed from mold 12 by using a lift that engages with lifting
anchors 234 to support
barrier wall 226. Front panel 42/front wall 20 (Figure 10) is then removed.
Extractors 168A
and 168B (Figure 3) are then used to separate barrier wall 226 from mold 12
and liner 140A
(Figure 7). The lift can then be used move barrier wall 226 to a storage
location where barrier
wall 226 is left in a vertical orientation while it is allowed to more
completely harden/cure prior
to final transport and use.
[0082] Once
barrier wall 226 is removed from mold 12, the above process can then be
repeated using mold 12 to form a new barrier wall 226. One of the additional
benefits of the
present invention is that because layers 206 and 210 are in the vertical
orientation during their
initial hardening/curing, barrier walls 226 can be removed relatively quickly
from mold 12,
thereby enabling more barrier walls 226 to be made from mold 12 for a fixed
time period. That
is, barrier walls 226 have more stability and structural strength in the
vertical orientation than in
a horizontal orientation. Thus, barrier walls 226 formed in horizontal
orientation must be left to
cure for a longer time period (relative to barrier walls formed in a vertical
orientation) before the
barrier walls can be removed from the mold and lifted to a vertical
orientation for storage and
further curing. For example, barrier walls 226 in a vertical orientation can
typically be removed
from mold after 24 hours, e.g., within 25 hours of being formed, while barrier
walls 226 formed
in a horizontal orientation may require at least 30 or 48 hours of curing
before they can be
removed from the mold and lifted to a vertical orientation without risk of
failure.
22
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[0083] Barrier wall 226 can have the alternative sizes and configurations
as previously
discussed with regard to compartment 60. Likewise, barrier wall 226 can have
the layers with
the various configurations and dimensions of cementitious material 208 and
noise absorbing
material 204 as previously discussed.
[0084] Figure 12 depicts an alternative method of forming an inventive
barrier wall using
mold 12. In this method, in contrast to forming layer 206 by using a curable
material that is
placed and leveled within mold 12, a layer 206A is first placed within mold 12
that is in the form
of a prefabricated panel 207. Prefabricated panel 207 is a self-supporting
structure that can be
comprised of the same materials used to form noise absorbing material 204,
previously discussed
herein, or can comprise a wood panel, a foam panel, or a composite panel made
from a
combination of the forgoing materials or other materials. Prefabricated panel
207 can have the
same noise absorbing properties as layer 206, i.e., can be more effective at
absorbing noise than
cementitious material 208. Furthermore, cementitious material 208 will
typically have a higher
compressive strength, tensile strength, and/or density, when cured, than
prefabricated panel 207.
[0085] Prefabricated panel 207 is shown as having a top surface 242 that
faces layer 210. A
plurality of spaced apart anchors 244 are mounted on panel 207 so as to
outwardly project from
top surface 242. Anchors 244 can be mounted during the fabrication of panel
207 or can be
attached after panel 207 is formed. Anchors 244 help facilitate secure
engagement between
panel 207 and layer 210 and can have a variety of different configurations. In
the depicted
embodiment, anchors 244 are formed having barbs 246.
[0086] During production, mold 12 is rotated to the horizontal orientation
as shown in Figure
12 and panel 207 is positioned within compartment 60. Cementitious material
208 is then placed
on top of top surface 242 of panel 207 in the same way, as discussed above,
that cementitious
material was placed on top of layer 206. Anchors 244 become embedded within
cementitious
material 208 and facilitate a secure engagement between panel 207 and layer
210 as cementitious
material subsequently hardens/cures. The same above process for forming
barrier wall 226 is
then continued to form a resulting barrier wall that includes panel 207. The
present invention
may be embodied in other specific forms without departing from its spirit or
essential
characteristics. The described embodiments are to be considered in all
respects only as
illustrative and not restrictive. The scope of the invention is, therefore,
indicated by the
23
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appended claims rather than by the foregoing description. All changes which
come within the
meaning and range of equivalency of the claims are to be embraced within their
scope.
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