Wall forming apparatus and methods

Abstract

A wall forming apparatus and methods having a series of walls that are movable to form molding compartments into which fluid concrete can be poured and allowed to harden to form a cement wall. Spacer members determine the width of the compartments and, accordingly, the thickness of the manufactured wall. Steel cables under tension maintain the integrity of the shape of the compartments when they are subjected to the pressure applied against the walls by the fluid concrete.

1 . A panel forming apparatus for manufacturing concrete wall panels, comprising:
 a superstructure having a first longitudinal side, a second longitudinal side, a proximal end side, and a distal end side, wherein said first and second longitudinal sides are attached to said proximal and distal end sides, said first and second longitudinal sides being substantially parallel and said proximal and distal end sides being substantially parallel, said superstructure being designed to withstand high pressures;   a plurality of wall forming panels slidably positioned substantially parallel to said first longitudinal side and said second longitudinal side, said wall forming panels capable of moving in the space between said first and second longitudinal sides to form a plurality of parallel hollow wall molding compartments, said parallel hollow wall molding compartments capable of receiving fluid concrete that hardens or cures to form said wall panels;   a plurality of spacer members forming opposite ends of said molding compartments to maintain a predetermined space between adjacent panels so that the thickness of the concrete panel is determined by the width of said spacer member;   a sealing member at the bottom of each molding component to inhibit concrete leakage from the bottom of said compartments; and   a tension system operable with said superstructure for maintaining the integrity of said first and second longitudinal sides of said superstructure, wherein said tension system comprises a tension wire cable capable of receiving a tensile force, and a tension cabling system, wherein said tension cabling system transfers said tensile force of said tension wire cable perpendicularly to the walls of said first and second longitudinal sides of said superstructure to maintain the integrity of said walls of said first and second longitudinal walls.   
   
   
       2 . Apparatus for varying the longitudinal length of a wall panel fabricated by hardening or curing a solidifying a mixture in a hollow wall molding compartment, comprising:
 a substantially rectangular block of low density material shaped and configured to be inserted into said hollow wall molding compartment prior to said solidifying mixture being introduced into said hollow wall molding compartment, said rectangular block being inserted to occupy a portion of space in said hollow wall molding compartment such that when said solidifying mixture hardens or cures, the longitudinal length of said wall panel fabricated in said hollow wall molding compartment is less than a similar wall panel hardened or cured in said hollow wall molding compartment when said short panel jig is absent.   
   
   
       3 . A panel forming apparatus for manufacturing wall panels, comprising:
 a superstructure being substantially rectangular in shape having a first longitudinal side, a second longitudinal side, a proximal end side, and a distal end side;   and at least one wall forming panel positioned in the interior of said superstructure being substantially parallel to said proximal end side and said distal end side and capable of moving in the space between said first and second longitudinal sides to form at least one hollow wall molding compartment, said hollow wall molding compartment capable of receiving a solidifying mixture to form said wall panel;   
   
   
       4 . The panel forming apparatus of  claim 3 , further comprising a tension system operable with said superstructure for maintaining the integrity of the walls of said first and second longitudinal sides, said tension system acting as a counter force to a force exerted by said solidifying mixture on said walls of said first and second longitudinal sides after said solidifying mixture is received in said parallel hollow wall molding compartments. 
   
   
       5 . The panel forming apparatus of  claim 4 , wherein said tension system comprises a tension wire cable capable of receiving a tensile force, and a tension cabling system, wherein said counter force is created by said tension cabling system transferring said tensile force of said tension wire cable perpendicularly to said walls of said first and second longitudinal sides. 
   
   
       6 . The panel forming apparatus of  claim 5 , wherein said tension system further comprises adjustable struts held perpendicular to said walls of said first and second longitudinal sides; a slotted receptacle for receiving said tension wire cable; and a screw apparatus, said screw apparatus functioning to adjust said tensile force of said tension wire cable by longitudinally lengthening or shortening said tension cabling system, wherein the lengthening or shortening of said tension cabling system functions to respectively stretch or relax said tension wire cable thereby adjusting said tensile force. 
   
   
       7 . The panel forming apparatus of  claim 4 , wherein said tension system is maintained in a stable horizontal orientation orthogonal to one of said first or second longitudinal sides by attaching one end of a cable at a distal end of said tension system and attaching the other end of said cable to the said one of said first or second longitudinal sides. 
   
   
       8 . The panel forming apparatus of  claim 3 , further comprising a short panel blank for varying the length of said wall panels, said short panel blank comprising a rectangular block of low density material configured to be inserted into at least one of said parallel hollow wall molding compartments to vary the length of said wall panels. 
   
   
       9 . The panel forming apparatus of  claim 3 , wherein the width of said wall panels is determined by a spacer, said spacer being positioned between juxtaposed wall forming panels. 
   
   
       10 . The panel forming apparatus of  claim 3 , wherein said solidifying mixture is comprised of cement and other materials such that said solidifying mixture hardens or cures to form concrete wall panels. 
   
   
       11 . The panel forming apparatus of  claim 10 , wherein steel rebar is supported within said parallel hollow wall molding compartments prior to said parallel hollow wall molding compartments receiving said solidifying mixture such that said concrete wall panels are structurally reinforced by said steel rebar. 
   
   
       12 . The panel forming apparatus of  claim 10 , wherein said solidifying mixture is vibrated by a series of vibrators prior to curing or hardening to remove trapped air bubbles from within said mixture of cement and other materials. 
   
   
       13 . The panel forming apparatus of  claim 3 , wherein a worker or operator may access the top of each parallel hollow wall molding compartment to perform operations within said parallel hollow wall molding compartment while said solidifying mixture is received into said parallel hollow wall molding compartment. 
   
   
       14 . The panel forming apparatus of  claim 3 , wherein said at least one wall forming panel is movably supported by steel V-groove wheels, wherein a first steel V-groove wheel is coupled with a proximal side of said at least one wall forming panel and operable with said first longitudinal side and a second steel V-groove wheel is coupled with a distal side of said at least one wall forming panel and operable with said second longitudinal side. 
   
   
       15 . The panel forming apparatus of  claim 3 , wherein a texture/pattern liner is attached on opposing wall forming panels so that a texture and/or pattern is formed on the finished concrete wall panel. 
   
   
       16 . The panel forming apparatus of  claim 15 , wherein a cap is placed on the top of said wall forming panel to prevent concrete from leaking between the panel and texture/panel liner. 
   
   
       17 . The panel forming apparatus of  claim 3 , wherein said wall panel is provided with a texture or pattern on at least one face of said wall panel by securing a liner to at least one of said at least one wall forming panels. 
   
   
       18 . The panel forming apparatus of  claim 3 , wherein said superstructure is shaped and configured to be capable of being attached to a movable platform for transporting said superstructure from a first location to a second location and forming said wall panels on said movable platform. 
   
   
       19 . The panel forming apparatus of  claim 18 , wherein said movable platform is a truck trailer. 
   
   
       20 . The panel forming apparatus of  claim 18 , wherein said trailer includes stabilizers for lifting the trailer wheels off of the ground before the solidifying mixture is supplied to said hollow molding compartment. 
   
   
       21 . A method of manufacturing a plurality of wall panels, comprising:
 positioning at least one wall forming panel to a desired position within a superstructure having a rectangular profile including a first longitudinal side, a second longitudinal side, a proximal end side, and a distal end side, such that said at least one wall forming panel forms a plurality of hollow wall molding compartments, said hollow wall molding compartments capable of receiving a solidifying mixture that hardens or cures to form said wall panels;   introducing said solidifying mixture into said hollow wall molding compartments;   allowing said solidifying mixture to cure or harden to form said wall panels; and   removing said wall panels from said superstructure after said solidifying mixture has sufficiently cured or hardened.   
   
   
       22 . The method of manufacturing of  claim 21 , further comprising the steps of:
 positioning said at least one wall forming panel in a first position, said first position accommodating a worker in applying a release agent to at least one of said at least one wall forming panel, said proximal end side, and said distal end side; positioning said at least one wall forming panel in a second position, said second position being said desired position within said superstructure to form said plurality of hollow wall molding compartments; and   positioning said at least one wall forming panel in a third position, said third position aiding in the removal or extraction of said wall panel from said hollow wall molding compartment.   
   
   
       23 . The method of manufacturing of  claim 21 , wherein said solidifying mixture is comprised of cement and other materials such that said solidifying mixture hardens or cures to form concrete wall panels. 
   
   
       24 . The method of manufacturing of  claim 22 , further comprising the step of positioning steel rebar within said hollow wall molding compartments prior to introducing said solidifying mixture into said hollow wall molding compartment such that said concrete wall panels are structurally reinforced. 
   
   
       25 . The method of manufacturing of  claim 21 , further comprising the step of positioning a rectangular block of low density material within at least one of said plurality of hollow wall molding compartments such that the longitudinal length of said wall panel formed in said at least one of said plurality of hollow wall molding compartments is less than the longitudinal length of a similar wall panel formed in said at least one of said plurality of hollow wall molding compartments when said rectangular block of low density material is absent. 
   
   
       26 . The method of manufacturing of  claim 21 , further comprising the step of positioning a spacer between one of said proximal end side or said distal end side and said at least one wall forming panel to vary the gap between said at least one wall forming panel and said proximal or distal end side; or positioning said spacer between said at least one wall forming panel and another of said at least one wall forming panel to vary the gap between said at least one wall forming panel and said other at least one wall forming panel. 
   
   
       27 . The method of manufacturing of  claim 21 , further comprising the step of inserting a rubber sealing mat at the bottom of each of said plurality of hollow wall molding compartments such that each of said plurality of hollow wall molding compartments is sealed with respect to another of said plurality of hollow wall molding compartments to prevent said solidifying material from leaking between said plurality of hollow wall molding compartments. 
   
   
       28 . The method of manufacturing of  claim 21 , further comprising the step of attaching a textured or patterned liner to at least one of said proximal end side, said distal end side, and said at least one wall forming panel to form a textured or patterned face on the respective wall panel associated with that said proximal end side, said distal end side, and said at least one wall forming panel. 
   
   
       29 . The method of manufacturing of  claim 21 , further comprising the step of placing said superstructure under stress to maintain the integrity of the walls of said first and second longitudinal sides by coupling a tension system to said superstructure, said tension system acting as a counter force to a force exerted by said solidifying mixture on said walls of said first and second longitudinal sides after said solidifying mixture is introduced into said plurality of hollow wall molding compartments. 
   
   
       30 . The method of manufacturing of  claim 29 , wherein said tension system comprises a tension wire cable capable of receiving a tensile force, and a tension cabling system, wherein said tension cabling system transfers said tensile force of said tension wire cable perpendicularly to said walls of said first and second longitudinal sides of said superstructure to maintain the integrity of said walls, and wherein said tension system further comprises: adjustable struts held perpendicular to said walls of said first and second longitudinal sides; a slotted receptacle for receiving said tension wire cable; and a screw apparatus, said screw apparatus functioning to adjust said tensile force of said tension wire cable by longitudinally lengthening or shortening said tension cabling system, wherein the lengthening or shortening of said tension cabling system functions to respectively stretch or relax said tension wire cable thereby adjusting said tensile force. 
   
   
       31 . The method of manufacturing of  claim 21 , wherein the step of removing said wall panels is performed by placing a steel cap on the top of said solidifying mixture before it solidifies, said steel cap attachable to hooks for connecting said wall panel to a removal mechanism, said steel cap becoming imbedded within said wall panel after said solidifying mixture cures or hardens. 
   
   
       32 . The method of manufacturing of  claim 21 , further comprising the step of lowering a series of vibrators into said plurality of hollow wall molding compartments after said solidifying mixture has been introduced into said plurality of hollow wall molding components, said series of vibrators acting to aid in the removal of air bubbles from within said solidifying mixture by vibrating said solidifying mixture within said plurality of hollow wall molding compartments. 
   
   
       33 . The method of manufacturing of  claim 21 , further comprising the step of placing said superstructure onto the bed of a trailer and securing said superstructure with respect to said trailer for the purpose of transporting said superstructure from a first location to a second location and manufacturing said wall panels on said trailer.