US20120247046A1

US20120247046A1 - Wall construction panels and methods for forming structures using wall construction panels

Info

Publication number: US20120247046A1
Application number: US13/073,309
Authority: US
Inventors: Scott Jewett; Harvey Jewett
Original assignee: PORTABLE COMPOSITES Inc
Current assignee: PORTABLE COMPOSITES Inc
Priority date: 2011-03-28
Filing date: 2011-03-28
Publication date: 2012-10-04

Abstract

One embodiment of the present invention provides a wall construction panel, comprising: a pair of walls connected by a plurality of stringers that allow the walls to be opened from a folded flat configuration to a popped open configuration; wherein the folded flat configuration allows for compact shipping; wherein the popped open configuration allows the walls to be filled with one or more tilling materials to provide strength, mass and/or impact resistance to the panel.

Description

TECHNICAL FIELD

The present invention relates generally to panel systems and structures, and more particularly to wall construction panels and methods for forming structures using wall construction panels.

DESCRIPTION OF THE RELATED ART

There exists a long-felt need for easily deployable, strong structures to provide, e.g., deployable buildings, revetment walls, temporary housing, walk-in refrigerators, food storage buildings, and computer server rooms.
The military, petrochemical industry, and other organizations have the need for easy to deploy, force resistant and/or insulated buildings. For example, deployable structures are needed every year in response to natural disasters such as earthquakes, tornados, floods, tsunamis, storms, and/or hurricanes occur in areas all over the world. These natural disasters often cause millions of dollars in damage and tremendous loss of life. The first hours and days of a natural disaster are critical to relief workers when attempting to mitigate the damage and casualties of the natural disaster area. However, the relief workers often have no place to stay due to the damage caused by the natural disaster to suitable shelters such as hotels, vacant apartments, or houses. In addition the displaced native population will generally utilize any vacancies in housing.
Because the building of even temporary housing is extremely time consuming and expensive and can require, for example, natural resources which may not be readily available in the affected areas, the critical first hours and days are wasted building housing for the relief workers rather than the displaced native population or are spent erecting temporary shelters that typically do not provide a long term solution for the displaced native population.
In the meantime, the critical first hours and days are not used efficiently since a limited amount of relief workers will be present, and furthermore, energy is wasted building housing for the limited amount of relief workers. This can lead to a high amount of damages and casualties.
Temporary solutions such as tents are generally unsatisfactory since they may not provide adequate shelter against extreme temperatures at night or the day. In addition, such temporary solutions are generally uncomfortable, which can fatigue and tax the rescue workers. This can reduce the efficiency of the rescue workers.
More permanent shelters are typically expensive both in terms of the purchase price and to transport to the location of the natural disaster. Thus, there is a need for a building which can be easily erected in an efficient manner while providing a comfortable and adequate shelter.
As another example, it is typical to construct walk-in refrigerators/freezers from panels of insulation, often urethane foam or fiberglass, covered in sheet metal. These panels are made in a production line and then linked together at the final site using a cam-lock system that compresses linear gaskets to create a connection and a seal at the seams. The cam-lock system is typically a hook that swings outward to engage a receiving pin on the adjacent panel. These cam-locks are expensive and complicated to install. They also require holes drilled into each cam-lock site in order to insert a tool to activate the locking action.
Constructing the insulated panels requires building a frame covered in sheet metal. The frame is often made of high-density urethane foam, metal, or wood. The sheet metal is then attached to both sides of the frame, as a canvas stretched over a frame, to yield an enclosed panel. This panel is retained in a large press, and liquid urethane foam is injected through a small opening. The foam then expands to fill the void. The foam's pressure is counteracted by the press. Once the foam cures, the finished panel is removed from the press. Making custom panel sizes requires that the frame and sheet metal panels be cut to desired sizes and then assembled. The foam also must be metered to ensure both that the panel is filled, and that not too much foam is wasted by overfilling.
The conventional method has a number of disadvantages. Almost all large refrigeration panels are constructed the same way. A frame with a tongue or groove exterior is fabricated using wood or high-density urethane foam. Both faces of the open frame are skinned in sheet metal. This assembly forms the exterior of the completed structurally insulated panel. The empty, metal-skinned frame is retained in a press and expanding urethane foam is injected. Once expanded, the panel s ready for assembly.
Attaching the panels together is accomplished with a cam and receiver pin system. Prior to skinning with sheet metal, cams are installed on one frame edge and the receiving panel edge has a receiving pin installed. An approximately ½″ hole is drilled through the sheet metal to allow the engagement of a tool used to rotate the cam device. Similar to turning the handle on a common sliding door latch, this swings a hook out to grab and engage the receiving pin on the opposing panel. As the panels are pulled snuggly together by the cams, rubber gaskets are used to effectuate a seal between the metal exteriors of the joined panels. This system is expensive, does not create a seamless connection, and requires drilling holes in the exterior finish. It also creates an area of reduced insulation, as the frame is a poor insulator. In addition, it creates an air-filled void in which the metal skins conduct heat. Further, the seams are a sanitation concern as they create a crevice for bacterial and fungal growth. An average-sized walk-in refrigerator often required the installation of hundreds of these cam devices and thus half as many access holes bored through the exterior sheet metal skins. Only half as many holes are drilled because one hole per set of cams is required (a set is a cam device and its receiving pin on the opposing panel). These holes are required to be capped and sealed per health department standards.
Prior art construction systems and methods for walk-in refrigerators require expensive, custom fabrication of frames. The cam and receiver connectors require significant labor, lower the insulation efficiency, and require boring holes in the exterior of the panels. Further, sheet metal dents easily. Colors require the application of an exterior paint that can scratch and flake. Such systems use metal, which is a poor insulator and makes the completed system heavy, and thus expensive to ship and difficult to assemble. Additionally, none of the prior art provides for improved insulation by eliminating the air gap between joined panels. All joining systems require metal or other poor insulator materials that come in contact with the inner and outer walls. The prior art also fails to provide for a seam fused or welded to eliminate crevices for bacteria or fungal growth. Moreover, conventional systems and methods do not use polymeric sheet stock for the exterior walls of the panel. Furthermore, conventional systems and methods do not use filament or cable for connecting panels.
In view of the above, there is a significant need for easily deployable, well-insulated structures to provide storage for items that require temperature control such as walk-in refrigerators, food storage buildings, computer server rooms, equipment rooms, freezers, etc.

BRIEF SUMMARY OF EMBODIMENTS OF THE INVENTION

Embodiments of the present invention provide wall construction panels and methods for forming structures using wall construction panels. The wall construction panels having outer walls that are attached parallel to each other using hinged connectors. These connectors may be referred to herein as “stringers.” The purpose of the stringers is to allow the panels to fold flat for shipping, thus providing a massive say n s in transportation costs.
One particular embodiment provides a wall construction panel, comprising: a pair of walls connected by a plurality of stringers that allow the walls to be opened from a folded flat configuration to a popped open configuration; wherein the folded flat configuration allows for compact shipping; wherein the popped open configuration allows the walls to be filled with one or more filling materials to provide strength, mass and/or impact resistance to the panel. In some embodiments, the articulating stringers are high strength stringers that hingedly connected at each end to a wall to permit the panel to be moved between the popped open configuration and the folded flat configuration. The stringers are disposed substantially parallel to the walls in the folded flat configuration, and disposed substantially perpendicular to the walls in the popped open configuration.
In one implementation, each stringer comprises a first looped end for connection to a first wire that is threaded through the first looped end within one wall, and a second looped end for connection to a second wire that is threaded through the second looped end within the other wall. A slot is provided in each wall for each looped end to provide space for the stringers to articulate between the popped open configuration and the folded flat configuration. The stringers may comprise a rigid material selected from the group consisting of wire, metal, plastic, and combinations thereof. The panel walls may comprise lightweight, inexpensive, stiff, plastic, planar surfaces. In some cases, the walls are perforated with holes to allow a filling material to migrate into the holes, thus providing a physical bond between the walls and filling material.
In various embodiments, the filling material may comprises earth, rubble, cement, sand, foam, and other suitable materials. In some cases, the foam is provided in a poly-bag pouch that features a separation means for separating two or more ingredients, wherein the separation means is breached in order to mix the ingredients.
Another embodiment of the invention is directed toward a method of connecting modular wall connection panels, each panel comprising a pair of walls connected by a plurality of articulating stringers that allow the walls to be opened from a folded flat configuration to a popped open configuration, wherein the folded flat configuration allows for compact shipping, wherein the popped open configuration allows the walls to be filled with one or more filling materials to provide strength, mass and/or impact resistance to the panel, the method comprising the step of connecting a first modular wall connection panel with a second modular wall connection panel.
In the above method, the step of connecting the first panel with the second panel comprises zipping the panels together using a sliding motion, thereby locking the panels together without the use of glue, pins, screws, or any other hardware. Additionally, each panel wall comprises an outside surface and an inside surface separated by spacers, and wherein some of the spacers are slotted to allow the first panel to slide in an overlapping manner with respect to the second panel. In some embodiments, the method further comprises the step of attaching the connected wall panels to an existing structure via anchoring means selected from the group consisting of cables, straps and high tensile strength anchors. Alternatively, the method may further comprise the step of attaching the connected wall panels to the ground using ground anchors selected from the group consisting of screw-in devices and spikes. In embodiments wherein the filling material comprises a foam, the method may further comprise providing a U-shaped tray under the bottom panel that forms a reservoir for the liquid foam, and seals the bottom of the wall upon hardening.
Other features and aspects of the invention will become apparent from the following detailed description, taken in conjunction with the accompanying drawings, which illustrate. by way of example, the features in accordance with embodiments of the invention. The summary is not intended to limit the scope of the invention, which is defined solely by the claims attached hereto.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention, in accordance with one or more various embodiments, is described in detail with reference to the following figures. The drawings are provided for purposes of illustration only and merely depict typical or example embodiments of the invention. These drawings are provided to facilitate the reader's understanding of the invention and shall not he considered limiting of the breadth, scope, or applicability of the invention, It should be noted that for clarity and ease of illustration these drawings are not necessarily made to scale.

FIGS. 1A and 1B are perspective views illustrating a wall construction panel in a folded flat configuration and a popped up configuration, respectively, in accordance with the principles of the invention.

FIGS. 2A-2E are perspective views illustrating a system and method of connecting a pair of wall connection panels in accordance with the principles of the invention.

FIG. 3 is a perspective view illustrating a multiple wall composite panel comprising three walls in accordance with the principles of the invention.

FIG. 4 is a perspective view illustrating various wall composite panels, each panel having a different types of filling material or combinations of filling materials, in accordance with the principles of the invention.

FIG. 5 is a perspective view illustrating alternative stringers for connecting walls in accordance with the principles of the invention.

The figures are not intended to be exhaustive or to limit the invention to the precise form disclosed. It should be understood that the invention can be practiced with modification and alteration, and that the invention be limited only by the claims an the equivalents thereof.

DETAILED DESCRIPTION OF THE EMBODIMENTS OF THE INVENTION

The present invention is directed toward a revolutionary wall construction system eluding a plurality of panels having outer walls that are attached parallel to each other using stringers to allow the panels to fold flat for shipping, thus providing a large savings in transportation costs.
The wall construction technology of the invention has many applications, including without limitation: walk-in coolers, emergency housing, blast resistant buildings for the military. Using this technology, buildings can be erected onsite in a matter of hours without the use of power tools. Composites have been used for years to make strong, light high performance parts but it has been considered impracticable to construct large items, such as buildings, from composites. However, the wall construction system set forth herein is highly insulated, strong, and designed for the US State Department as protection against terrorist attacks.
Referring to FIGS. 1A and 1B, a wall construction panel 100 for use on a wall construction system, in accordance with the principles of the invention, will now be described. Particularly, the wall construction panel 100 includes a pair of walls 110, 120 that are connected by a plurality of stringers 130, which allow the walls 110, 120 to be flipped opened from a folded flat configuration (as depicted in FIG. 1) to a popped open configuration (as depicted in FIG. 1). In the open configuration, the gap between these planar walls 110, 120 is filled with foam, sand, cement, earth, rubble, or other filling materials and combinations thereof, that provide strength and structural rigidity to the structure. On the other hand, the flat configuration allows for compact shipping. As set forth herein, the wall construction panel 100 has manifold applications such as emergency housing, blast resistant buildings and coolers.
In one embodiment, the wall construction panel 100 features high strength articulating stringers 130 hingedly connected at each end to a wall to permit the panel to be moved between the popped open configuration and the folded flat configuration. Specifically, the stringers 130 are substantially parallel to the walls 110, 120 in the flat configuration, and rotated such that they are substantially perpendicular to the walls 110, 120 in the popped open configuration. As such, the wall construction panel 100 can be shipped in the flat configuration and popped open the construction site. Each end 150 of stringer 130 is looped for connection to a wire 160 that is threaded through the looped end 150 within the wall 110, 120. In addition, a slot 170 is provided in each wall 110, 120 for each looped end 150 to provide space for the stringer 130 to articulate between configurations. In some embodiments, the stringers 130 comprise a rigid material such as wire, metal, plastic, or a composite.
In one embodiment, the wall construction panel 100 in the folded flat configuration is less than 1″ thick, and pops open to form a predetermined wall thickness. By way of example, this predetermined wall thickness may be 3″ thick, 4″ thick, 5″ thick, etc., depending up the application. In some embodiments, each wall 110, 120 is 1-c-thick twin-wall plastic; however, other suitable materials may be employed. The plastic walls 110, 120 are Class 1 fire retardant, strong and ductile, and form a smooth, strong exterior finish. As such, the wall construction panel 100 includes stiffer planar surfaces with less weight and cost. In certain embodiments of the invention, the inner surface of the twin-wall panel may be perforated to allow for foam (or other filling material) to migrate into the holes, thus providing a physical bond between the walls and filling material. In further embodiments, the outer surface of the walls may be clad with a material such as hardened steel, aluminum, or other suitable material. This cladding may be attached using an adhesive, rivets, screws or other means.
It has been determined that certain filling materials are more useful for particular applications. For example, foam may be preferred for applications that require structure and insulation. In addition, cement may be selected as the filling material for applications that require strength and mass. Other applications that require blast and force resistance may use sand, rubble and/or earth as the filling material. This type of filling material is typically cheap and locally available.
FIGS. 2A-2E illustrate a system and method of connecting a pair of wall connection panels 100, 200 in accordance with the principles of the invention. In particular, any number of panels 100, 200 may be zipped together using a sliding motion to form larger structures. Accordingly, this locking system may be employed to connect any number of modular panels 100, 200 without the need for glue, pins, screws, or any hardware.
Referring now to FIG. 2A, two modular panels 100, 200 are depicted in their popped open configuration prior to being connected together. Arrow 215 represents the direction that panel 100 is moved with respect to panel 200 in order to connect or zip the panels 100, 200 together. Specifically, each panel wall 110, 120 of panel 100 comprises an outside surface 125 and an inside surface 135 that are separated by spacers 145, whereas each panel wall 210, 220 of panel 200 comprises an outside surface 225 and an inside surface 235 that are separated by spacers 245. The panels 100, 200 are slid or zipped together such that the inner and outer surfaces 125, 135 of panel 100 fit together with the inner and outer surfaces 225, 235 of panel 200 in an overlapping manner. In the illustrated embodiment, the bottom spacers 145A, 145B of panel wall 100 and the top spacers 245A, 245B of panel wall 200 are slotted in order to allow sliding movement of wall surface 135 within panel wall 200 and sliding movement of wall surface 225 within panel wall 100.
FIG. 2B depicts panel 100 being zipped together with panel 200, while FIG. 2C depicts the panels 100, 200 after they have been zipped together. Once the panels have been connected, the overlapping slotted spacers 145A, 145B, 245A, 245B prevent the panels 100, 200 from being pulled apart unless they are slid apart in the direction of arrow 215 (or the opposite direction). FIG. 2D is an enlarged view showing details of the interconnections between panels 100, 200. As illustrated in FIG. 2D, certain spacers 145A, 145B, 245A, 245B are slotted to facilitate the connection of adjacent panels 100, 200 when they are zipped together. Particularly, the slotted spacers 145A. 145B, 245A, 245B allow the panels 100, 200 to be slidably connected such that the panel wall surfaces 125, 225, 135, 235 overlap with surface 125 comprising the outermost surface and surface 235 comprising the innermost surface. After the walls 100, 200 are connected together, the overlapping spacers 145A, 245A, 1458, 245B (in order from top to bottom) also act as a locking mechanism to prevent separation unless a panel is pulled in the direction of arrow 215 (or the opposite direction). FIG. 2E is an enlarged view of a spacer 145, including loops 150 on each end for receiving the wire 160 within a panel wall.
FIG. 3 illustrates a multiple wall composite panel 300 comprising three walls 310, 320, 330 that are connected by a plurality of stringers 330, which allow the walls 310, 320, 330 to be flipped opened from a folded flat configuration (not shown) to a popped open configuration as depicted. In the open configuration, these planar walls 310, 320, 330 are filled with foam, sand, cement, earth, rubble or other filling materials and combinations thereof, that provide strength and structural rigidity to the structure. In other embodiments, a composite panel may be formed by attaching a pair of wall panels 100, 200 side-by-side, for example using an adhesive, screws, or other known fastening means. Additional embodiments may include a multiple wall panels featuring three or more panels. All of the multiple wall configurations allows for the production of a composite wall panel 300 having two or more filling materials.
Once at the job site, the panels 100, 200 are flipped open and connected such that they are ready to be filled using a suitable filling material such as foam, sand, earth, etc. Referring to FIG. 4, various panels 400, 410, 420, 440 are depicted to illustrate several types of filling materials and combinations of filling materials. In particular, panel 400 is filled with a proprietary expandable rigid foam (i.e., urethane) to yield a once-piece composite (SIP) building that is strong and insulated. In some embodiments, the foam may be provided in a foam bag such as a poly-bag pouch for easy preparation. The foam bag may feature a separation means for separating two or more ingredients, wherein the separation means is ruptured or otherwise breached in order to mix the ingredients. A user may simply breach the separation means shake the foam poly-bag pouches for about 20 seconds, and pour into a wall panel.
With further reference to FIG. 4, wall panel 410 is filled with a locally available organic material, such as hay or grass, to provide a low cost, insulated wall. In another embodiment, composite wall panel 420 comprises a first panel 425 filled with urethane foam to provide strength and insulation and a second panel 430 filled with sand to provided a high-mass blast, ballistic, or collision wall. In a further embodiment, panel 440 is filled with a Kevlar blanket for ballistic resistance as well as foam to provide additional strength and insulation. Other filling material options may include without limitation, (i) concrete for a reinforced concrete wall system, (ii) rubble or recyclable trash for inexpensive emergency relief, (iii) rigid ballistic panels or insert panels, and (iv) any other suitable material that provides strength, insulation, blast resistance, and/or mass. As would be appreciated by those of skill in the art, any combination of wall panels and filling materials may be employed in response to site conditions without departing from the scope of the invention.
FIG. 5 is a perspective view illustrating alternative stringers 530, 535 for connecting walls (sheet stock 540) in accordance with the principles of the invention. For sheet stock 540 that is not twin-wall or corrugated, the stringers 530, 535 can be attached with any suitable means for connection including, but not limited to, u-nails, u-bolts, or wire loops. In the illustrated embodiment, stringer 530 having looped ends 550 is attached to sheet stock 540 via a single attachment u-nail 555, whereas t-shaped stringer 535 having linear ends 560 is attached to sheet stock 540 via a pair of u-nails 555. In various embodiments, the sheet stock 540 might be wood, cementous board, fiber reinforced board, plastic, composite or other suitable materials. The stringers 530, 535 can be rigid materials including without limitation, metal, plastic, cord, wire, or string or composites.
According to further embodiments of the invention, a wall construction panel may be formed from two or more walls that are connected together without the use of mechanical connectors. Instead, the walls feature a deep surface profile (i.e., texture on the inner surface) or are perforated with holes to allow the filling material to form a physical bond with the walls. More particularly, the filling material forms a physical bond with the rough wall surfaces or holes such that the panels can be made in a press without stringers or other mechanical connectors to hold the walls together. Similar to previous embodiments, the walls are filled with one or more filling materials to provide strength, mass and/or impact resistance to the panel.
As set forth herein, composites have been used for years to make strong, light high performance parts. However, it has long been considered impracticable to construct large items (such as buildings) from composites. Various embodiments of the present invention change the paradigm by providing systems and methods for producing composite structures such as buildings and walk-in freezers that: (i) are easy to build without the need for power tools; (ii) are force resistant and use almost no fragment-able materials; (iii) are highly insulated with an R-25 rating for a 4″ wall thickness; (iv) are transportable with a shipping volume approximately ⅛th that of typical buildings/walls; (v) have a Class 1 fire resistance rating; (vi) provide 24,000 pounds of tensioned anchoring for extraordinary wind and blast resistance; and/or (vii) provide flexible technology that can be used for everything from blast shelters to emergency housing. Additionally, the total cost of ownership is a fraction of almost any other building method.
Testing was performed using a foam-filled panel having the following dimensions: 96×20″ and 4″ thick. Deflection strength was measured at over 56 times panel weight for an 8 foot span. Moreover, at 19.6 pounds, this panel resisted loading of 1,100 pounds without panel failure. Testing also revealed a deflection of 8.25″ with full recovery when unloaded.
In some embodiments of the invention featuring the use of a foam, a tray or a “U” shaped stud (e.g., made of steel) may be employed to form the bottom of the wall. The tray slides into the notches in the twin-wall sheets, thus forming a reservoir for the liquid foam. Upon hardening, the foam seals the bottom of the wall, and mitigates leakage.
According to various embodiments of the invention, a structure formed using the systems and methods described herein may be attached to an existing structure (e.g., a roof) by use of any suitable form of anchoring means. By way of non-limiting example, the anchoring means may comprise strapping of cable, straps, or high tensile strength material. In addition, other embodiments may feature a structure that is attached to the ground using ground anchors. For example, such ground anchors may include without limitation, screw-in devices and/or spikes.
Although the invention is described above in terms of various exemplary embodiments and implementations, it should be understood that the various features, aspects and functionality described in one or more of the individual embodiments are not limited in their applicability to the particular embodiment with which they are described, but instead can be applied, alone or in various combinations, to one or more of the other embodiments of the invention, whether or not such embodiments are described and whether or not such features are presented as being a part of a described embodiment. Thus, the breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments.
Terms and phrases used in this document, and variations thereof, unless otherwise expressly stated, should be construed as open ended as opposed to limiting. As examples of the foregoing: the term “including” should be read as meaning “including, without limitation” or the like; the term “example” is used to provide exemplary instances of the item in discussion, not an exhaustive or limiting list thereof; the terms “a” or “an” should be read as meaning “at least one,” “one or more” or the like; and adjectives such as “conventional,” “traditional,” “normal,” “standard,” “known” and terms of similar meaning should not be construed as limiting the item described to a given time period or to an item available as of a given time, but instead should be read to encompass conventional, traditional, normal, or standard technologies that may be available or known now or at any time in the future. Likewise, where this document refers to technologies that would be apparent or known to one of ordinary skill in the art, such technologies encompass those apparent or known to the skilled artisan now or at any time in the future.
The presence of broadening words and phrases such as “one or more,” “at least,” “but not limited to” or other like phrases in some instances shall not be read to mean that the narrower case is intended or required in instances where such broadening phrases may be absent. Additionally, the various embodiments set forth herein are described in terms of exemplary block diagrams, flow charts and other illustrations. As will become apparent to one of ordinary skill in the art after reading this document, the illustrated embodiments and their various alternatives can be implemented without confinement to the illustrated examples. These illustrations and their accompanying description should not be construed as mandating a particular architecture or configuration.

Claims

1. A wall construction panel, comprising:

a pair of walls connected by a plurality of articulating stringers that allow the walls to be opened from a folded flat configuration to a popped open configuration;

wherein the folded flat configuration allows for compact shipping;

wherein the popped open configuration allows the walls to be filled with one or more filling materials to provide strength, mass and/or impact resistance to the wall construction panel;

wherein the wall construction panel is zipped together with a further wall construction panel using a sliding motion, thereby locking the wall construction panel and the further wall construction panel without using glue, pins, screws, or any other hardware;

wherein each of the walls comprises an outside surface and an inside surface separated by a plurality of spacers; and

wherein some of the plurality of spacers are slotted to allow the wall construction panel to slide in an overlapping manner with respect to the further wall construction panel.

2. The wall construction panel of claim 1, wherein the articulating stringers are high strength stringers that are hingedly connected at each end to one of the walls to permit the wall construction panel to be moved between the popped open configuration and the folded flat configuration.

3. The wall construction panel of claim 2, wherein the stringers are disposed substantially parallel to the walls in the folded flat configuration, and disposed substantially perpendicular to the walls in the popped open configuration.

4. The wall construction panel of claim 2, wherein each stringer comprises a first looped end for connection to a first wire that is threaded through the first looped end within one wall, and a second looped end for connection to a second wire that is threaded through the second looped end within the other wall.

5. The wall construction panel of claim 4, wherein a slot is provided in each wall for each looped end to provide space for the stringers to articulate between the popped open configuration and the folded flat configuration.

6. The wall construction panel of claim 4, wherein the stringers comprise a rigid material selected from the group consisting of wire, metal, plastic, and combinations thereof.

7. The wall construction panel of claim 1, wherein the walls comprise lightweight, inexpensive, stiff, plastic, planar surfaces.

8. The wall construction panel of claim 1, wherein the walls comprise twin walls or corrugated sheet stock.

9. The wall construction panel of claim 1, wherein the walls are perforated with holes to allow a filling material to migrate into the holes, thus providing a physical bond between the walls and filling material.

10. The wall construction panel of claim 1, wherein a filling material comprises earth or rubble.

11. The wall construction panel of claim 1, wherein a filling material comprises cement.

12. The wall construction panel of claim 1, wherein a filling material comprises sand.

13. The wall construction panel of claim 1, wherein a filling material comprises a foam.

14. The wall construction panel of claim 13, wherein the foam is provided in a poly-bag pouch that features a separation means for separating two or more ingredients, wherein the separation means is breached in order to mix the ingredients.

15. The wall construction panel of claim 1, wherein the outside surface of the walls includes a hardened steel cladding.

16. A method of connecting modular wall connection panels, each panel comprising a pair of walls connected by a plurality of articulating stringers that allow the walls to be opened from a folded flat configuration to a popped open configuration, wherein the folded flat configuration allows for compact shipping, wherein the popped open configuration allows the walls to be filled with one or more filling materials to provide strength, mass and/or impact resistance to the panel, the method comprising:

connecting a first modular wall connection panel with a second modular wall connection panel.

17. The method of claim 16, wherein connecting the first panel with the second panel comprises zipping the panels together using a sliding motion, thereby locking the panels together without the use of glue, pins, screws, or any other hardware.

18. The method of claim 17, wherein each panel wall comprises an outside surface and an inside surface separated by spacers, and wherein some of the spacers are slotted to allow the first panel to slide in an overlapping manner with respect to the second panel.

19. The method of claim 16, further comprising the step of attaching the connected wall panels to an existing structure or the ground via anchoring means selected from the group consisting of cables, straps and high tensile strength anchors.

20. The method of claim 16, further comprising the step of attaching the connected wall panels to the ground using ground anchors selected from the group consisting of screw-in devices and spikes.

21. The method of claim 16, wherein the first panel comprises the top panel and the second panel comprises the bottom panels, and wherein the filling material comprises a foam.

22. The method of claim 21, further comprising providing a U-shaped tray under the bottom panel that forms a reservoir for the liquid foam, and seals the bottom of the wall upon hardening.

23. A multiple wall construction panel, comprising:

a plurality of walls including at least first, second and third walls, wherein the first and second walls are connected by a plurality of articulating stringers that allow the walls to be opened from a folded flat configuration to a popped open configuration, and wherein the second and third walls are connected by a plurality of articulating stringers that allow the walls to be opened from a folded flat configuration to a popped open configuration;

wherein the folded flat configuration allows for compact shipping;

wherein the popped open configuration allows the walls to be filled with one or more filling materials to provide strength, mass and/or impact resistance to the panel.

24. A wall construction panel, comprising:

a pair of walls connected together without the use of mechanical connectors;

wherein the walls are filled with one or more filling materials to provide strength, mass and/or impact resistance to the panel;

wherein the walls include a deep surface profile or are perforated with holes to allow the filling material to form a physical bond with the walls.