Patent Application
20080115427
This invention relates generally to the field of construction and more particularly, but not by way of limitation, to methods and apparatus for forming curved structures, such as curved walls, archways, barrel ceilings and round columns.
Typically, straight wall construction uses a runner attached to the floor structure and a corresponding runner attached to the ceiling structure (or free floating) with studs positioned between and attached to the runners. The runners and studs form a structural frame suitable for supporting gypsum board, such as SHEETROCK™, or other wall covering. Construction of other straight line structures relies on these same principles. Common construction practices use wooden 2×4's and 2×6's (approximate dimensions of boards in inches) to form the runners and studs.
These standard materials and methods are suitable for a major portion of most construction, however, curved structures, such as curved walls, archways, barrel ceilings and round columns are frequently desired for their architectural styling. While the principles for constructing curved structures are much the same as those for constructing straight structures, formation of such structures typically requires significantly more cuts in the runners and studs to form the desired radius. As a result, several track designs formed from sheet metal have been developed to reduce the amount of labor and waste associated with the construction of curved structures. While the sheet metal runners have been accepted as improvements over standard construction techniques, many are unwieldy and are difficult to position and retain in a desired position. Additionally, it should be noted that those skilled in the art commonly refer to devices for constructing curved structures as tracks, plates and runners interchangeably.
Thus, further improvements in the field of runners for constructing curved walls are necessary. In particular, it would be desirable to provide a runner which is readily compatible with conventional framing practices. Such a runner should provide adequate strength, minimal labor requirements, cost efficiency and flexibility in application. In particular, there is a need for an improved runner which may be readily formed and retained in a desired radius. Further, there is a need for an apparatus which is compatible with conventional framing operations such as nailing, toe-nailing and other conventional construction techniques.
The present invention provides improved apparatus and methods of forming a curved structure which meet the needs described above.
In one embodiment, the current invention provides a runner for forming curved structures. The runner comprises at least two sections capable of being arranged on a radius. Each section has at least two staggered layers. More preferably, each section has at least three layers with at least one layer being staggered. Each layer has a first end with a concave portion. Preferably the concave portion is located between two tabs. Additionally, each layer has a second end with at least a portion of the second end having a convex configuration. Preferably, the convex portion carries a centrally located protrusion.
In another embodiment, the current invention provides a runner for forming curved structures. The runner comprises at least two sections with each section having at least three layers. Preferably each layer used to form the section is substantially identical. Each layer has an upper surface, a lower surface, opposing side walls, a first end and a second end. The first end has a concave portion located between two tabs with the transition from the tabs to the sidewalls being defined by tangential sidewalls. Thus, the tangential sidewalls join the tabs to the sidewalls. At least a portion of the second end is a convex portion. The convex portion is defined by a radial arc which is preferably less than 180 degrees. The convex portion is joined to the sidewalls by tangential walls. When assembled as a section, at least one layer is offset and reversed from the next upper or lower layer. Thus, the second end of the offset layer extends beyond the first end of at least one other layer.
In still another embodiment, the current invention provides a runner for forming curved structures. The runner comprises at least two sections with each section having at least two layers. Each layer has a first end with a concave portion located between two tabs. Additionally, each layer has a second end which includes a central convex portion, at least two arcuate tabs and at least two arcuate recesses.
In yet another embodiment, the current invention provides a runner for forming curved structures. The runner comprises at least two sections, each section having at least two substantially identical layers. Preferably, each section has at least three identical layers. Each layer has an upper surface, a lower surface, opposing side walls, a first end and a second end. The first end includes a centralizer portion located between two recesses. Positioned adjacent to each recess is at least one tab wherein the tabs are joined to the sidewalls by tangential walls. The second end includes a central convex portion, at least two arcuate tabs and at least two arcuate recesses. The distance between the arcuate tabs is less than the maximum width of the layer and the arcuate tabs are joined to the sidewall by tangential walls. When assembled as a section, at least one layer is offset and reversed from another layer such that the second end of the offset layer extends beyond the first end of at least one other layer.
In yet another embodiment of the current invention, a runner is provided comprised of two or more sections. Each section is an integral component which carries at least two outwardly projecting extensions with each extension have at least a partial convex configuration. Additionally, each section carries at least two recesses having a concave area. More preferably, each section carries at least three outwardly projecting extensions and has at least three recesses with concave areas. When the sections are assembled as a runner, the convex portion of one extension is received within a corresponding concave area of the adjacent section's recess.
Additionally, the current invention provides an embodiment which is particularly suited for forming archways. The runner suitable for forming archways comprises at least two sections. Each section carries a plurality of extensions or flanges with at least two extensions projecting from one side of the section and at least one extension projecting from the opposite side of the section. The extensions define gaps which correspond in configuration to the dimensions of the extensions. A runner is prepared by positioning the extension(s) of one section within the gap(s) of an adjacent section. Preferably, each extension includes a passageway suitable for receiving a pin or dowel. The pin or dowel secures adjacent sections to one another and defines a pivot point between adjacent sections. The resulting pivot point is preferably below the midpoint of the section. Thus, the resulting runner will form an arc in only a single direction.
Still further, the current invention provides a method for preparing a structural base for a curved surface. The method of the current invention comprises providing two or more sections capable of being arranged and secured on a radius. The sections comprise at least two layers with at least one layer offset or staggered from another layer. If more than two layers are used in the section at least two layers are positioned directly above one another. Preferably each layer is substantially identical. A runner for forming the curved structure is prepared by positioning one section adjacent to another section by inserting the second end of one layer into the first end of an adjacent layer. Following assembly, the sections are placed on the desired radius and secured.
The preferred embodiments of the present invention will be discussed with reference to the attached drawings. When discussing the various embodiments of the current invention, like reference numbers refer to like parts throughout the drawings and this description.
The three layered embodiment is particularly preferred in applications which will experience axial loading. Under conditions of axial loading, the use of three layers 14 will prevent flexing of joints 30. Excessive flexing of joints 30 will likely result in separation of adjacent sections 12. Typically, separation may occur as flexing will result in loss of pivot pins 33 from holes 32. Additionally, such flexing may release nails or other similar devices 35 used to fix adjacent sections 12 on a desired radius. However, the preferred three layer embodiment resists flexing due to the overlap of layers 14 between adjacent sections 12.
Sections 12 are assembled to provide runner 10 for constructing a curved surface. Except for the terminating sections 12 of runner 10, each end 26 of one layer 14 is positioned within end 16 of an adjacent layer 14.
In the preferred embodiments depicted by several of the Figures, including 1, 4, 6, 13 and 21, the resulting joint 30 is sufficiently tight so as to substantially preclude the passage of water and air. Preferably, joint 30 is water tight. Further, protrusion 28 and tabs 22, 24 cooperate to define the radius of movement of adjacent sections 12. Cooperation of tabs 22, 24 with protrusion 28 also prevents shearing of the pivot pin 33 located within hole 32 due to over rotation of sections 12. Thus, tabs 22, 24 carry the resulting load from positioning and securing runner 10 thereby precluding application of lateral and twisting forces to pin 33.
Additionally, tabs 22, 24 and protrusion 28 provide low friction points by minimizing surface area contact between sections 12 thereby reducing the load on the pivot pin during positioning of sections 12. Further, when positioned on a tight radius such that protrusion 28 is in contact with either tab 22 or tab 24 the other tab 22, 24 will contact one tangential wall 34. Thus, tangential wall 34 also acts as a stop to further preclude tension on pivot pin 33. As used herein, tangential wall 34 is an angled wall joining or defining end 26 to sidewall 38 such that end 26 has an overall width less than the width—W—of layer 14. Therefore, for the purposes of this disclosure, tangential walls 34 and 42, 44 are not defined by a line which is necessarily perpendicular to the radius of the arc. Rather, tangential walls 34, 42 and 44 define a reduced area suitable to provide the clearance necessary to preclude undesired corners when runner 10 is placed on a radius.
Further, symmetries of the preferred embodiment are demonstrated by
With reference to
The current invention preferably utilizes identical layers 14 to prepare section 12. Layer 14 has multiple symmetries which simplify production of runner 10 while eliminating several steps during construction of curved surfaces. As shown best in
In a preferred embodiment, at least one hole 32 passing through layer 14 is provided a distance from end 26 and centrally located between the sides of layer 14. Further, in the preferred embodiment offset layer 14b is offset a distance such that hole 32 in the offset layer 14b aligns with hole 32 in layers 14a and 14c when two or more sections 12 are joined together to form runner 10. Thus, the aligned holes 32 define a pivot point between adjacent sections 12. In the preferred embodiment, a pin or dowel 33 is positioned within this pivot point, i.e. hole 32, thereby securing adjacent sections 12 to one another in a pivotal relationship. This embodiment allows for fine adjustment of runner 10 prior to securing adjacent sections 12 to one another in a nonpivotal relationship.
As depicted by
Use of nail 35 or similar device to secure adjacent sections creates a shear pin effect by penetrating at least two layers 14 of section 12. Preferably, nail 35 penetrates into at least a third layer 14. In the preferred embodiment, layer 14 is a solid material throughout the structure of layer 14. Use of a solid structure increases the surface area in contact with nail 35 thereby reducing the likelihood of nail 35 being twisted or flexed out of section 12 by application of axial and/or lateral forces on section 12. Finally, to enhance the securing strength of nail 35, nail 35 is preferably located a substantial distance from pin 33.
While the embodiment of
In one preferred embodiment of runner 10 depicted in
While one preferred embodiment of the current invention 10 utilizes sections 12 comprising at least three layers 14, embodiments comprising greater or fewer layers are also contemplated by the current invention. For example, if the axial strength of runner 10 is not critical, then a two layer embodiment as depicted in
As noted above, layers 14 in each embodiment will preferably have substantially identical designs. However, the thickness of each layer 14 may vary. Thus, as used herein a substantially identical layer 14 may differ in thickness from other layers 14 within the same section 12 and other sections 12 of runner 10. Preferably, each layer 14 has an identical geometric configuration aside from thickness.
In the embodiments of
Preferably when using metal strip 50, pivot hole 32 is omitted from layer 14. In this embodiment, metal strip 50 carries a pivot hole or pivot point 52 which permits pivotal movement of adjacent sections 12. While metal strip 50 may have a width corresponding to the width of layer 14, more preferably, metal strip 50 will be centered on layer 14 and have a width between about 20% to about 50% of the width of layer 14. Finally, if glue hole 46 is provided along with metal strip 50, glue hole 46 is preferably positioned in area outside of the area covered by metal strip 50. Further, a second glue hole (not shown) is preferred to ensure adequate locking of adjacent sections 12.
Metal strip 50 comprises a series of strips 51 which may be joined in a pivotal relationship. As depicted in the Figures, pivot point 52 is formed by combining an eyelet (not shown) and an eyelet receiving hole (not shown). Techniques for forming eyelets and eyelet receiving holes are well known to those skilled in the art. As known to those skilled in the art, properly securing eyelet 56 within eyelet receiving hole permits pivotal movement of adjacent strips 51 in relation to one another. Pivot points 52 of this type are advantageous due to the ease and cost efficiency of manufacturing.
In the preferred embodiment discussed above, layers 14 of the present invention are prepared from wood, plywood, oriented strand board, particle board plastic, (including expanded or foamed versions such as foam pvc) or wood/plastic composites or other composite materials suitable for receiving nail 35. As used herein, a material suitable for receiving a nail will be any composition which will permit a nail to be installed within its body while providing resistance against a substantial portion of the sides of the nail such that the nail is retained and resists the tendency to be extracted or rejected from the material. A finely woven network or honeycomb of synthetic material would likely be suitable to receive a nail. However, thin walled or hollow materials do not provide sufficient retention on the nail as an insufficient portion of the nail's surface contacts the material.
The currently preferred material for layer 14 includes solid wood or oriented strand board. Use of these materials allows for construction of curved walls or other curved surfaces using conventional framing techniques. Thus, following positioning and securing of runner 10 in the desired radius, studs may be positioned and nailed to runner 10 without using special techniques.
In the preferred embodiments discussed above and below, layer 14 may optionally include surface treatments designed to further improve construction techniques of curved walls and archways. For example as depicted in
With reference to
Layer 114 differs primarily from layer 14 by providing a lower length to width ratio. Thus, manufacture of layer 114 generates less waste. Further, to accommodate a lower length to width ratio, concave recess 20 of layer 14 has been replaced with a centralizer portion 120 which includes a concave portion or recess 121 positioned between smaller arcuate tabs 122 and 124. Centralizer portion 120 provides a self centralizing feature during assembly of adjacent sections 12. Centralizer portion 120 fills much of the area previously vacated by concave recess 20. As a result, the self centralizing aspect of layer 114 also increases the surface area of end 16. The increased surface area strengthens joint 30 and improves the effectiveness of glue or other device such as nail 35 used to secure runner 10 in position. Finally, as in the prior embodiment, layer 114 carries range defining tabs 22 and 24 on first end 16.
Second end 26 of layer 114 has also been modified to correspond to and be readily received within end 16 of an adjacent layer 114. As shown in
As shown in
This embodiment is also designed to preclude undesired corners when positioned on a radius. As depicted in
As discussed above with regard to the embodiment depicted in
As noted above, the current invention is useful for forming both curved walls and archways. Depending on the width of the archway, a three layer runner 10 may be insufficient. Although multiple layers beyond three layers may be used in the current invention, the alternative embodiment of
A simplified embodiment of the current invention is provided in
The embodiment of
Another simplified embodiment of the current invention is depicted by
In the embodiments discussed above, sections 12 are preferably prepared by assembly of individual layers 14. However, as depicted in
Section 212 also includes at least three recesses 216. At least one recess 216 is located between two generally convex extensions 226 on first side 227. Second side 229 includes at least two recesses 216 on opposing sides of extension 226. Each recess 216 preferably terminates at tabs 222 and 224 which define stops and concave area 220. Concave area 220 is defined by a radius which is concentric with convex extension 226 when measured from passageway 232 and preferably has a depth corresponding to the length of protrusion 228. Tabs 222 and 224 are joined to sidewall 238 by tangential walls 242 and 244 respectively. As depicted in
Although section 212 has been described with at least three generally convex extensions 226 and three recesses 216, one skilled in the art will recognize that section 212 will perform satisfactorily with only two convex extensions 226 and two recesses 216. Such an embodiment would generally correspond to the embodiment discussed above with reference to
In another alternative embodiment depicted in
The embodiment of
As depicted side 344 carries four extensions 326 which define alternating gaps or recesses 320 and side 346 carries three extensions 326 defining recesses 320. Recesses 320 preferably have widths corresponding to the width of extensions 326. Additionally each extension 326 carries a passageway 332 which acts as a pivot point for adjacent sections 312. In the preferred embodiment a pin 333 or dowel rod or other similar device is received within passageway 332 to secure adjacent sections 312 to one another in a pivotal manner.
Since archways generally do not require radii in two directions, runner 310 can be designed to pivot in a single direction. As depicted in
Preferably, as depicted in
Those skilled in the art will recognize that runner 310 can be modified to provide a runner capable of providing radii in at least two directions by moving passageway 332 to the vicinity of the midpoint or center line of section 312. Finally, as discussed above, and depicted in
The method for assembling runners 10, 210 and 310 and constructing a curved surface are essentially identical. Thus, the following description of preparing a curved surface will focus on the embodiment of
Other embodiments of the current invention will be apparent to those skilled in the art from a consideration of this specification or practice of the invention disclosed herein. However, the foregoing specification is considered merely exemplary of the current invention with the true scope and spirit of the invention being indicated by the following claims.
