1. Field of the Invention
The present invention generally relates to an arched jamb for providing arched wall openings, such as doorways, windows and the like, and, more particularly, is concerned with a standardized arched jamb assembly and method.
2. Description of the Prior Art
Arched jambs provide arched wall openings, such as doorways, in homes. Arched jambs generally cost more than conventional rectangular jambs but they dramatically enhance the aesthetic appeal and thus the market value of homes.
Prior art arched jambs typically have an upper arched jamb member which defines the top of the arched wall opening and a pair of upright jamb members which define the opposite sides of the wall opening. The upright jamb members have upper end portions which support the upper arched jamb member at its opposite ends. For aesthetic reasons, the upper arched jamb member is typically positioned at a standard height above the floor no matter what the width of the wall opening is between the upright jamb members. Thus, as the width of the wall opening or distance between the upright jamb members changes, the arched jamb members are utilized that have varying radii of curvature. Heretofore, such variation of arched jamb member curvatures has been accommodated by varying the configurations of the features that support the opposite ends of the arched jamb member which, in turn, accounts for a part of the greater costs of construction of arched jambs over conventional rectangular jambs.
For example, in one prior art arched jamb A as shown in
In another prior art arched jamb disclosed in U.S. Pat. No. 6,128,864 to Barry et al., an upper elliptical arched assembly is made of a center arched member and two opposite side members attached to the center arched member. Each of the side members are cut with a taper at both end portions thereof. The side members are cut along respective first and second cut lines that form the tapered end portions. The first cut line is angled along the top portion of the side member such that the top surface of the top end portion of the side member is substantially parallel to the bottom surface of the center arched member when these pieces are attached together. Also, the second cut line is angled along the bottom end portion of the side members such that the top surface of the bottom end portion of the side members is substantially parallel to an inner row of wall studs, or upright members, when attached thereto. So in this prior art arched assembly, three separate pieces with two different radii of curvature are attached to each other to form a single arched assembly. Each side member is configured to transition the radius of curvature of the center arched member into the radius of curvature of each side member which requires different cuts to accommodate different radii of curvature. Thus, the upper arched assembly of this prior art arched jamb would add still further costs rather than reduce costs of arched jambs compared to conventional rectangular jambs.
From the foregoing discussion, it is readily understood that neither of these two prior art arched jambs seem to provide an effective solution of the aforementioned problem. Consequently, a need exists for an innovation which will provides a simple and inexpensive solution to the problem found in prior art arched jamb of an arched wall opening without introducing any new problems in place thereof.
The present invention provides a standardized arched jamb assembly and construction apparatus and method designed to satisfy the aforementioned need. The arched jamb assembly of the present invention introduces standardization in the sense that cuts made on the opposite ends of an arched jamb member and in the upper end portions of upright jamb members, that form the interfaces there between in the arched jamb assembly, have the same angular configurations, and thus are made standard, irrespective of the curvature of the upper arched jamb member and the horizontal distance between the upright jamb members which is the same as the width of the wall opening defined by the standard arched jamb assembly. The construction apparatus and method of the present invention provide simple and inexpensive tools, techniques and structure for use in constructing the standardized arched jamb assembly.
Accordingly, the present invention is directed to a standardized arched jamb assembly which comprises: (a) an arched jamb member having a pair of opposite ends and first angled cuts made on the opposite ends, the arched jamb member also having a predetermined curvature and radius of curvature; and (b) a pair of opposite upright jamb members having upper end portions and second angled cuts made in the upper end portions which meet and interface with the first angled cuts (notched cuts) on the opposite ends of the arched jamb member so as to assemble the arched jamb member with the upright jamb members to form an arched jamb assembly for defining a wall opening, the first and second angled cuts of the arched jamb member and upright jamb members being comprised of two sides and having substantially identical standard configurations irrespective of variations in the radius of curvature of the upper arched jamb member provided to define wall openings of different widths between the upright jamb members.
The present invention also is directed an apparatus for constructing an arched jamb member for an arched jamb assembly. The apparatus comprises: (a) a fixture having opposite ends and adapted to stationarily hold an arched jamb member such that opposite ends of the arched jamb member (or at least one end) extend outwardly from the opposite ends of the fixture; and (b) cutting means for making an angled cut at each of the opposite ends of the arched jamb member such that an apex is formed by the angled cut that protrudes outwardly from the respective opposite end of the arched jamb member.
The present invention further is directed to a method for constructing an arched jamb assembly which comprises the steps of: (a) making an angled end cut at each of a pair of opposite ends of an arched jamb member such that an apex is formed by the angled cut, preferably a right angle, that protrudes outwardly from the respective one of the opposite ends of the arched jamb member; (b) making an angled notch cut in an inner corner of each of the upper end portions of a pair of upright jamb members such that the angular configurations of the angled end cuts and angled notch cuts are substantially the same; and (c) placing the arched jamb member on the upper end portions of the upright jamb members such that the angled end cuts of the arched jamb member meet and interface with the angled notch cuts of the upright jamb members so as to assemble the arched jamb member with the upright jamb members to form an arched jamb assembly for defining a wall opening.
The present invention further allows for the fabrication of a standardized angled cut for the protrusion of the arched jamb member and notch of the upright jamb members and the standardized location and structure of the notch on the upright jamb members thereby avoiding the custom fabrication of openings depending upon the opening width. Further, the application of these standardized notch and protrusions provides substantial standardization of fabrication techniques.
According to another aspect of the present invention, an arched jamb assembly with an integral stop is provided, which comprises an arched jamb member having opposite ends, an upper face and a lower face, the arched jamb member having a stop portion extending along its lower face between its opposite ends, the stop portion having opposite ends, a pair of opposite upright jamb members for installing on opposite sides of a wall opening with the arched jamb member extending between the upright jamb members to frame the opening, each upright jamb member having an upper end portion and an inner face, and an upright stop member extending along the inner face and having an upper end portion adjacent the upper end portion of the upright jamb member, the arched jamb member having first angled cuts on its opposite ends, each angled cut comprising a first cut extending from the upper face, a second cut extending inwardly from said first cut into the end of said stop portion, and a third cut extending downwardly from said first cut to a lower face of said stop portion, and each upright jamb member having second angled cuts in the upper end portions of said upright jamb member and stop member, the second angled cuts being comprised of two sides only, whereby the first cut at a respective end of said arched jamb member engages a first side of said second angled cut when the arched jamb member is engaged between said upright jamb members, the second cut engages a second side of said second angled cut, and the third cut engages an outer face of the upright stop member.
The two sides of the second angled cuts may be at right angles to one another, with the first cut being vertical and the second cut being generally horizontal when the upright jamb members are installed in a door opening. The second cut extends across part of the width of the upright jamb member and the entire width of the stop member, which may also be formed integrally with the upright jamb member. The first cut and third cut of the arched jamb member extend parallel to one another in a generally vertical direction, while the second cut extends transversely between the first and second cuts. The first and second sets of angled cuts will be easy to make.
In the prior art arched jamb assemblies with stop members, the stop members were typically formed separately from the arched jamb member and upright jamb member, and then attached to the respective arched and upright jamb members by nails or the like. The ends of the stop members were cut separately from the jamb members prior to attachment of the stop members to the jamb members. This makes the assembly more complex and adds expense. In the present invention, all that is necessary is to make two perpendicular cuts simultaneously in the upper ends of the upright jamb member and two perpendicular cuts at opposite ends of the arched jamb member, and to make an additional perpendicular cut simultaneously at each end of the stop portion. The addition of the stops to the arched jamb assembly will improve stability of the overall structure.
According to another aspect of the present invention, a method of making an arched jamb assembly is provided, which comprises the steps of:
These and other features and advantages of the present invention will become apparent to those skilled in the art upon a reading of the following detailed description when taken in conjunction with the drawings wherein there is shown and described an illustrative embodiment of the invention.
In the following detailed description, reference will be made to the attached drawings in which:
The arched jamb member 12 of the assembly 10 has a pair of opposite ends 16, predetermined curvature “x” and radius of curvature “y”, and a pair of first angled cuts 18 each made on one of the opposite ends 16 of the arched jamb member 12. Each upright jamb member 14 of the assembly 10 has an upper end portion 20 and a second angled cut (or notch) 22 made in the upper end portion 20. The first angled cuts 18 of the arched jamb member 12 respectively meet and interface with the second angled cuts 22 of the upright jamb members 14 so as to assemble the arched jamb member 12 with the upright jamb members 14 to form the arched jamb assembly 10 that defines a wall opening 24 below the upper arched jamb member 12 and between the lateral upright jamb members 14 of the assembly 10.
Referring to
More particularly, the two sides 18A, 18B of the angled end cuts 18 of the arched jamb member 18 and the two sides 22A, 22B of the angled notch cuts 22 of the upright jamb members 14 are preferably formed at substantially right angles such that, when the arched jamb member 12 and upright jamb members 14 are assembled into the arched jamb assembly 10, a first side 18A, 22A of each of the two-sided angled end cuts 18 and two-sided angled notch cuts 22 are horizontally-oriented, whereas a second side 18B, 22B of each of the two-sided angled end cuts 18 and two-sided angled notch cuts 22 is vertically-oriented. The width “w” of the horizontally-oriented first side 18A, 22A is “maintained constant” whereas the height “h” of the vertically-oriented second side 18B, 22B varies as the curvature “x” and radius of curvature “y” of the upper arched jamb member 12 varies in defining wall openings 24 of different widths and the same standard height. The height “h” of the angled notch cut 22B of the upper jamb member is preferably maintained constant but may vary as the curvature “x” and radius of curvature “y” of the upper arched jamb member 12 varies.
The opposite ends 16 of the arched jamb member 12 and the upper end portions 20 of the upright jamb members 14 can be secured together in any suitable manner. One possible way to secure them together is by a conventional screw S, such as seen in
Referring to
The cutting means 32 of the apparatus 28 is adapted to make the angled end cut 18 at each of the opposite ends 16 of the arched jamb member 12 such that the apex 18C formed by the angled end cut 18 protrudes outwardly from the respective opposite end 16 of the arched jamb member 12. The cutting means 32 preferably is a cutting tool which per se is conventional, such as one utilizing a dado blade 40, and adapted to make a substantially right-angled cut. The cutting means 32 thus provides the two sides 18A, 18B of each of the angled end cuts 18 with the first side 18A being the horizontally-oriented side and the second side 18B being the vertically-oriented side of the arched jamb member 12 in the assembled arched jamb assembly 10. The cutting means 32 also provides a constant width to the horizontally-oriented first side 18A and a variable height to the vertically-oriented second side 18B which varies as a radius of curvature of the upper arched jamb member 12 varies to define wall openings 24 of different widths. The angled notch cut 22 can be made in the upper end portion 20 of each of the upright jamb member 14 in a conventional manner by using a conventional tool, such as a saw, router or the like, so as to provide an angled notch cut 22 (preferably right angled) identical in configuration to that of the angled end cut 18.
The cutting means 32 of the apparatus 28 may be linked or connected by any conventional means by mechanical linking, pneumatic controls or other conventional means such that the end cut 18 at each of the opposite ends are performed at substantially the same time. Alternatively, the cutting means 32 of the apparatus 28 for each end may be separate such that the end cuts are performed separately. The fixture 30 may be rotated from a first orientation to a second orientation such that only one cutting means 32 is required (not shown). The cutting means 32 may include separate horizontal and vertical cutters that are either linked or independent (not shown).
From the foregoing description of the exemplary embodiments of the arched jamb assembly 10 and construction apparatus 28, an exemplary method for constructing the arched jamb assembly 10 has the following steps. An angled end cut 18 is made at each of the opposite ends 16 of the arched jamb member 12 such that the apex 18C formed by the angled end cut 18 protrudes outwardly from the respective one of the opposite ends 16 of the arched jamb member 12. An angled notch cut 22 is made in the inner corner 26 of each of the upper end portions 20 of the upright jamb members 14 such that the width ‘W’ of the angled end cuts 18 and angled notch cuts 22 are substantially the same. The arched jamb member 12 at its opposite ends 16 is placed on the upper end portions 20 of the upright jamb members 14 such that the angled end cuts 18 of the arched jamb member 12 meet and interface with the angled notch cuts 22 of the upright jamb members 14 so as to assemble the arched jamb member 12 with the upright jamb members 14 to form the arched jamb assembly 10 for defining the wall opening 24.
Arched jamb assemblies are commonly used with additional stop members for more stability.
The problem of using a standard stop assembly arrangement as in
In the previous embodiment, which had no built-in stop members or portions, the arched jamb member had first angled cuts at its opposite ends, each having two perpendicular sides 18A and 18B, while the upright jamb members had indents at their upper ends for receiving the cut ends of the arched jamb member, each indent also having two perpendicular sides 22A and 22B. In this embodiment, opposite ends of the arched jamb member 60 and stop portion 62 have angled cuts each comprised of three sides 68A, 68B and 68C, with sides 68A and 68B forming a right angled outer corner 68D and sides 68B and 68C forming a right angled inner corner or indented corner 68E. The cut 68B extends inwardly from the end of the arched jamb member and partially into the stop portion 62, while the cut 68C extends from corner 68E to the lower face 70 of the stop portion 62. Cut side 68A is perpendicular to the adjacent cut side 68B, while cut side 68B is perpendicular to cut side 68C. All three cut sides can be formed simultaneously, for example in the manner illustrated in
The upright jamb members each have a second angled cut at their upper end, which has two perpendicular sides 72A and 72B, similar to the second angled cut of the previous embodiment, apart from the fact that horizontal cut 72B is an integral cut extending across part of the upright jamb member 64 and across the upper end of the stop portion 65. It can be seen that this is much simpler than the arrangement of
In this embodiment, the angled cuts are formed simultaneously in the jamb members and stop portions or members, and each set of angled cuts includes an integral cut across part of a jamb member and across the stop portion or member, i.e. cut 68B of the arched jamb member and cut 72B of the upright jamb member. This allows the cuts in each jamb member to be formed simultaneously in a one step operation, rather than requiring a separate cutting step for one or both stop members, which simplifies manufacture and assembly. Additionally, all the cuts, including the stop cut, will be at essentially the same angles regardless of the curvature of the arched jamb member. As in the embodiment of
It is thought that the present invention and its advantages will be understood from the foregoing description and it will be apparent that various changes may be made thereto without departing from its spirit and scope of the invention or sacrificing all of its material advantages, the forms hereinbefore described being merely exemplary embodiments thereof.
This application is a Continuation In Part of application Ser. No. 09/954,683 filed Sep. 11, 2001 now U.S. Pat. No. 6,647,673.
Number | Name | Date | Kind |
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391463 | Ellis | Oct 1888 | A |
4955168 | Barry | Sep 1990 | A |
5245802 | Davis | Sep 1993 | A |
5526618 | Thomas | Jun 1996 | A |
5584148 | Barry et al. | Dec 1996 | A |
6401405 | Hicks | Jun 2002 | B1 |
Number | Date | Country | |
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20040068941 A1 | Apr 2004 | US |
Number | Date | Country | |
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Parent | 09954683 | Sep 2001 | US |
Child | 10682587 | US |