Polystyrene foamed plastic wall apparatus and method of construction

Claims

What is claimed is:

1. A wall apparatus comprising:

at least one panel supported by at least two polystyrene plastic support columns each of which has a central hollow and a reinforcing structural member secured to a support base,

at least one structural fastener which secures the at least one panel and at least one of the at least two columns together; and

an exterior finish applied to the entire wall apparatus.

2. A wall apparatus according to claim 1 wherein the structural fastener is at least one reinforcing bar which attaches the at least one panel and the at least one of the at least two columns together.

3. A wall apparatus according to claim 2 wherein the at least one reinforcing bar attaches the at least one panel and at least two columns together and is a pair of L-shaped, reinforcing bars.

4. A wall apparatus according to claim 2 wherein the at least one reinforcing bar which attaches the at least one panel and the at least one of the at least two columns together is a straight reinforcing bar laid in a recessed groove in the top of the at least one panel and the at least two columns with U-shaped joints that attach the bar to the columns.

5. A wall apparatus according to claim 4 wherein the straight reinforcing bar is comprised of multiple reinforcing bars that are tied together.

6. A wall apparatus according to claim 1 wherein the reinforcing structural member for each of the columns is a reinforcing bar.

7. A wall apparatus according to claim 1 wherein the support base for each of the reinforcing structural members is comprised of a concrete footing.

8. A wall apparatus according to claim 1 wherein the wall apparatus is made to be part of a fence.

9. A wall apparatus according to claim 1 further comprising a filler in the central hollow of each column.

10. A wall apparatus according to claim 9 wherein the filler provides structural support to the columns.

11. A wall apparatus according to claim 10 wherein the reinforcing filler is concrete.

12. A wall apparatus according to claim 1 wherein the at least one panel is at least one polystyrene plastic panel.

13. A wall apparatus comprising:

at least one polystyrene plastic panel supported by at least two support columns each of which has a central hollow and a reinforcing structural member secured to a support base;

at least one structural fastener which secures the at least one panel and at least one of the at least two columns together; and

an exterior finish applied to the entire wall apparatus.

14. A wall apparatus comprising:

at least one panel supported by at least two polystyrene plastic support columns each of which has a reinforcing structural member secured to a support base;

at least one reinforcing bar which secures the at least one panel and at least one of the at least two columns together; and

an exterior finish applied to the entire wall apparatus.

15. A wall apparatus according to claim 14 wherein the at least one reinforcing bar attaches the at least one panel and at least two columns together and is a pair of L-shaped, reinforcing bars.

16. A wall apparatus according to claim 14 wherein the at least one reinforcing bar which attaches the at least one panel and the at least one of the at least two columns together is a straight reinforcing bar laid in a recessed groove in the top of the at least one panel and the at least two columns with U-shaped joints that attach the bar to the columns.

17. A wall apparatus according to claim 16 wherein the straight reinforcing bar is comprised of multiple reinforcing bars that are tied together.

18. A wall apparatus comprising:

at least one polystyrene plastic panel supported by at least two support columns each of which has a reinforcing structural member secured to a support base;

at least one reinforcing bar which secures the at least one panel and at least one of the at least two columns together; and

an exterior finish applied to the entire wall apparatus.

19. A method of constructing a wall apparatus comprising the steps of:

structurally reinforcing at least two polystyrene plastic support columns in the ground wherein each column has a central hollow;

attaching at least one panel to the at least two support columns;

structurally fastening the at least one panel and at least one of the at least two columns together; and

applying an exterior finish to the entire wall apparatus.

20. A method of constructing a wall apparatus comprising the steps of:

structurally reinforcing at least two support columns in the ground wherein each column has a central hollow;

attaching at least one polystyrene plastic panel to the at least two support columns;

structurally fastening the at least one panel and at least One of the at least two columns together; and

applying an exterior finish to the entire wall apparatus.

21. The method of constructing a wall apparatus according to claim 20 wherein the step of structurally reinforcing the columns in the ground comprises the steps of:

securing a reinforcing structural member to a support base in the ground for each column;

placing each column on one of the support bases with the reinforcing member extending into the hollow of the column; and

filling the hollow of each column with a reinforcing filler.

22. The method of constructing a wall apparatus according to claim 20 wherein the step of applying an exterior finish to the entire wall apparatus comprises the steps of:

placing a netted mesh over the entire wall apparatus; and

applying stucco material to the exterior of the netted mesh to enhance strength and appearance of the wall apparatus.

23. The method of constructing a wall apparatus according to claim 20 wherein the step of applying an exterior finish to the entire wall apparatus comprises the step of applying paint to an exterior of the wall apparatus.

24. A method of constructing a wall apparatus comprising the steps of:

structurally reinforcing at least two polystyrene plastic support columns in the ground;

attaching at least one panel to the at least two support columns;

using at least one reinforcing bar to structurally fasten the at least one panel and at least one of the at least two columns together; and

applying an exterior finish to the entire wall apparatus.

25. A method of constructing a wall apparatus comprising the steps of:

structurally reinforcing at least two support columns in the ground;

attaching at least one polystyrene plastic panel to the at least two support columns;

using at least one reinforcing bar to structurally fasten the at least one panel and at least one column together; and

applying an exterior finish to the entire wall apparatus.

26. A panel fence comprising:

at least one polystyrene plastic panel held in place by a pair of H-shaped polystyrene plastic columns secured to a footing by a column reinforcing member; and

a top rail comprising a continuous length of a fence reinforcing member laid in a groove at the top edge of the entire fence.

27. A panel fence according to claim 26 further comprising:

a stucco coating applied to the surface of the fence.

28. A panel fence according to claim 26 further comprising:

a brick veneer finish applied to the surface of the fence.

29. A panel fence according to claim 26 wherein:

the footing is concrete.

30. A panel fence according to claim 26 wherein:

the column reinforcing member is steel rebar.

31. A panel fence according to claim 24 wherein the fence reinforcing member is steel rebar.

32. A method of making a polystyrene plastic fence comprising:

supporting each of at least two H columns having a central hollow on a concrete footing by placing each column over a rebar which is secured in the concrete footing and extends into the central hollow of each column,

then, pouring concrete into the central hollow so that each column structure is reinforced to the rebar and the footing, and

supporting at least one polystyrene plastic panel between the at least two H-columns.

33. The method of making a polystyrene plastic fence according to claim 32 wherein the step of supporting each of at least two columns further comprises the step of supporting each of at least two polystyrene plastic H columns on the concrete footing.

34. The method of making a polystyrene plastic fence according to claim 32 further comprising the step of:

using at least one reinforcing bar to structurally fasten the at least one panel and at least one of the at least two H columns together.

35. A method of making a polystyrene plastic fence comprising:

supporting each of at least two polystyrene plastic H columns having a central hollow on a concrete footing by placing each column over a rebar which is secured in the concrete footing and extends into the central hollow of each column;

then, pouring concrete into the central hollow so that each column structure is reinforced to the rebar and the footing; and

supporting at least one panel between the at least two H columns.

36. The method of making a polystyrene plastic fence according to claim 35 further comprising the step of:

using at least one reinforcing bar to structurally fasten the at least one panel and at least one of the at least two H columns together.

BACKGROUND OF THE INVENTION

1. The Field Of The Invention

The present invention relates generally to a Polystyrene Foamed Plastic Wall Apparatus and its method of construction, and more particularly, to an outside STYROFOAM.TM. polystyrene plastic fence comprised of at least one panel supported between at least two H-columns and associated reinforcing and attaching features and exterior finish.

.sup.1 A trademark for a light, resilient polystyrene plastic.

2. DISCUSSION OF BACKGROUND AND PRIOR ART

Walls and fences are manufactured from different types of materials. Some of the more common types of materials that walls and fences are made of are wood, brick, masonry block, or wire. Wood walls or fences have the disadvantage in that they can be more easily damaged or chipped.

The surface of a wood wall or fence begins to weather down after a period of time, and pieces of the wall or fence have to be replaced on a periodic basis. A wood wall or fence is not as sturdy as the other types of walls or fences, and it may not stand up against the wind as well as the others.

A wire wall or fence is also not as sturdy or solid as the other types of fences. Typically, a wire wall or fence encompasses a certain area, but the surface of the wall or fence is usually not covered. A wire wall or fence also has the disadvantages of a person being able to cut through it, or a person bending the surfaces or sides of the wire wall or fence.

Brick or masonry block type walls and fences have the advantage of being strong and sturdy. They hold up very well against the wind, and they are not easily broken. They have the further advantage in that stucco can be applied to the surface of the wall or fence to create a more appealing aesthetics especially for a wall or fence that can be matched to the exterior of a house. These types of walls or fences have been required by certain municipal housing or zoning laws.

Brick or block masonry type walls or fences, however, have several disadvantages. They are more expensive because they require significant time, labor, and material to construct. Another problem with these types of walls or fences is that the top row of bricks or blocks can be easily knocked off. These brick and masonry block type walls or fences have the further problem of weight settling which in effect causes ladder cracks in the surfaces and sides of the wall or fence.

Thus, there is not available on the market today a wall or fence that is mainly constructed of polystyrene foamed plastic that is fairly sturdy, that provides an appealing aesthetic look, that is easy and inexpensive to construct, and that would not have chipping or cracking problems.

SUMMARY OF THE INVENTION

Set forth below is a brief summary of the invention in order to overcome the foregoing problems and achieve the foregoing and other objects and advantages in accordance with the purposes of the present invention as embodied and broadly described herein.

One aspect of the invention is a wall or fence apparatus that is mainly constructed of polystyrene plastic material, and more particularly, STYROFOAM.TM. polystyrene plastic and its method of construction.

A second aspect of the invention is that the wall or fence comprises at least one styrofoam panel supported within at least two reinforced H-columns anchored in the ground, and an exterior finish for the entire wall or fence.

A third aspect of the invention is the method of manufacturing a wall or fence that is mainly constructed of polystyrene plastic material and, more particularly, STYROFOAM.TM. polystyrene plastic.

Further features of the invention include various shaped columns to form T's and corners that fit the panels in various ways and various reinforcing structures and attaching features that provide various ways of holding the columns and panels together and to the ground.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and form a part of the specification, illustrate several embodiments of the present invention and together with the description, serve to explain the principles of the invention. In the drawings:

FIG. 1--Perspective view of the Polystyrene Foamed Plastic Wall Apparatus with open portion showing the inner parts of the wall with the L-shaped attachment bars.

FIG. 2--2--2 cross-sectional side elevation view of the Polystyrene Foamed Plastic Wall Apparatus of FIG. 1 with cross-sectional portions showing the inner parts of the wall.

FIG. 3--3--3 top plan view of the Polystyrene Foamed Plastic Wall Apparatus of FIG. 2.

FIG. 4--4--4 cross-sectional elevation view of the Polystyrene Foamed Plastic Wall Apparatus of FIG. 1.

FIG. 5--Perspective view of the Polystyrene Foamed Plastic Wall Apparatus with U-joints and straight bar attachments.

FIG. 6--6--6 cross-sectional elevation view of the Polystyrene Foamed Plastic Wall Apparatus of FIG. 5.

FIG. 7--Perspective view of two straight reinforcement bars that are tied together and placed on top of the Polystyrene Foamed Plastic Wall Apparatus.

FIG. 8--Perspective view of a first embodiment in-line column which is an H-column and a panel that is attached to the H-column.

FIG. 9--Perspective view of a second embodiment corner column where two panels are attached perpendicularly to the column.

FIG. 10--Perspective view of a third embodiment T-column where three panels are attached in a T-shape configuration to the column.

FIG. 11--Perspective view of an in-line H-column showing a second embodiment of the panel that can be inserted in the groove of the H-column.

FIG. 12--Perspective view of a fifth embodiment column where the column has no attached panels.

FIG. 13--Perspective view of a sixth embodiment column where the column is attached to a different type of panel.

DETAILED DESCRIPTION OF THE INVENTION

As seen in FIG. 1, the wall apparatus 10 comprises panel(s) 20 that are inserted in the grooves of the columns 30 so that the panels and columns fit snugly together. These columns and panels are made of STYROFOAM.TM. polystyrene plastic, which is best described as a well known polystyrene foamed plastic. The columns 30 are secured in the ground so that they firmly stand up to support the panel(s) 20. The panel(s) 20 are then fastened to the columns 30. An exterior finish 90 is then applied to the entire wall structure.

The Columns

The columns 30 may have various shapes depending on the function of the column and the number and ways the panels 20 are to be attached, as seen in FIGS. 8-13 which are merely exemplary of some embodiments.

FIG. 8 shows a column 30 as an in-line, H-column in which the panel 20 is inserted in the groove of the column 30. The H-columns provide two in-line grooves opposite sides of the hollow 60. A series of panels 20 and columns 30 can be connected together in a line in order to create a length of wall that is any desired length.

FIG. 9 shows a corner-column 30 which is shaped to have two panels 20 attached perpendicularly to each other. These columns and panels are often used to create the corner of a wall or a fence.

FIG. 10 shows a T-column 30 which is shaped to have three panels 20 attached to each other in a T-shape configuration. This configuration is useful when using a wall portion to separate two areas.

FIG. 11 shows an in-line H-column 30 with panel 20 configured with a tongue 21 and integral wider portions 22, 23 which would typically be used when creating a flush-looking wall or fence.

FIG. 12 shows a completely enclosed column 30 with double hollows 60. Panels cannot be secured to this type of column 30 which is used to make a post that can have a variety of uses.

FIG. 13 shows an A-column 30 which is used as an end column to which an L-shaped stud 70 may be anchored to which a two-by-four 71 may be secured to which a gate 72 may be hung, for example. This embodiment differs from FIG. 11 in that the shape of the panel 20 that is secured in the groove of column 30 of FIG. 13 would have a trapezoidal shaped tongue rather than a square shaped tongue.

The Panels

The panels 20 also have different embodiments that are made of various shapes and sizes. The main important feature of the panels 20 is the shape of the tongue that will have to fit into the groove of the columns 30. Therefore, the type of panel 20 that is used to construct a wall will depend on the type of columns 30 that are used since the columns and panels have to fit snugly together.

FIG. 8 shows a perspective view of a first embodiment of the panels 20 in which the panel is a rectangular box shape with a width that would fit into the groove of the column 30. This is one of the more typical embodiments that would be used. However, the configuration that is c