U.S. patent application number 10/774282 was filed with the patent office on 2005-08-25 for apparatus and method for forming a dual radius arch mounting structure.
Invention is credited to Barry, Michael A., Goodwin, George E..
Application Number | 20050183347 10/774282 |
Document ID | / |
Family ID | 34860812 |
Filed Date | 2005-08-25 |
United States Patent
Application |
20050183347 |
Kind Code |
A1 |
Barry, Michael A. ; et
al. |
August 25, 2005 |
Apparatus and method for forming a dual radius arch mounting
structure
Abstract
An apparatus and method is provided for forming a dual radius
arch frame structure. The apparatus includes a longitudinal member
having a centerline and centerpoint. A laterally adjustable support
is further included which has one end attached to the centerpoint
of the longitudinal member in a perpendicular orientation and a
vertical support attached to a distal end of the laterally
adjustable support. A left outer form is provided which has a
generally semi-circular shaped arch centered and oriented about a
left pivot axis located on the centerline a predetermined distance
from the centerpoint. A right outer form is also provided which has
a generally semi-circular shaped arch centered and oriented about a
right pivot axis located on the centerline a predetermined distance
from the centerpoint. Additionally, an arched shaped center cord is
adapted to be connected to a receiving edge of the left outer form
and of the right outer form in a tangentially continuous manner.
Also, at least one adjustable left strut assembly interconnects the
left outer form to the vertical support and at least one adjustable
right strut assembly interconnects the right outer form to the
vertical support.
Inventors: |
Barry, Michael A.; (Irvine,
CA) ; Goodwin, George E.; (Anaheim, CA) |
Correspondence
Address: |
Kit M. Stetina
STETINA BRUNDA GARRED & BRUCKER
Suite 250
75 Enterprise
Aliso Viejo
CA
92656
US
|
Family ID: |
34860812 |
Appl. No.: |
10/774282 |
Filed: |
February 6, 2004 |
Current U.S.
Class: |
52/86 |
Current CPC
Class: |
B32B 21/02 20130101;
B32B 1/00 20130101; B27H 1/00 20130101; B32B 2419/00 20130101; B32B
21/13 20130101; B32B 21/042 20130101; B27D 1/083 20130101 |
Class at
Publication: |
052/086 |
International
Class: |
E04B 001/32 |
Claims
What is claimed is:
1. An apparatus for forming a dual radius arch frame comprising: a
longitudinal member having a centerline and centerpoint; a
laterally adjustable support having one end attached to the
centerpoint of said longitudinal member in a perpendicular
orientation and a vertical support attached to a distal end of said
laterally adjustable support; a left outer form having a generally
semi-circular shaped arch centered and oriented about a left pivot
axis located on the centerline a predetermined distance from the
centerpoint; a right outer form having a generally semi-circular
shaped arch centered and oriented about a right pivot axis located
on the centerline a predetermined distance from the centerpoint; an
arched shaped center cord adapted to be connected to a receiving
edge of said left outer form and of said right outer form in a
tangentially continuous manner; at least one adjustable left strut
assembly interconnecting said left outer form to said vertical
support; and at least one adjustable right strut assembly
interconnecting said right outer form to said vertical support.
2. The apparatus according to claim 1, further comprising a set of
preformed arched shaped center cords each having a different shape,
wherein each center cord may be separately installed into said
apparatus to vary the size of the dual radius arch frame to be
formed.
3. The apparatus according to claim 2, wherein at least one of a
radius measurement R.sub.3 and arc length measurement l of each
cord may be varied.
4. The apparatus according to claim 1, further comprising a
matching set of preformed left and right outer forms, each matching
set having a different radius R.sub.4, wherein each matching set
may be installed into said apparatus to vary the size of the dual
radius arch frame to be formed.
5. The apparatus according to claim 1, wherein the dual radius arch
frame is defined by a width W, arch height H, span length L and
thickness T.
6. The apparatus according to claim 1, wherein the dual radius arch
frame is defined by a left and right outer form radius R.sub.4 and
wherein said center cord has a radius R.sub.3 and arc length
measurement l.
7. The apparatus according to claim 6 wherein the left and right
pivot axis are equally spaced a distance 1/2L-R.sub.4 from the
centerpoint of said longitudinal member.
8. The apparatus according to claim 1, further comprising a center
strut assembly interconnecting said left outer form and said right
outer form.
9. The apparatus according to claim 1, in combination with a
plurality of laminate sheets conformally wrapped around said left
outer form, said center cord, and said right outer form.
10. The apparatus according to claim 9, further comprising a
plurality of winch assemblies attached to said vertical support,
said winch assemblies connected to a plurality of respective
individual straps wrapped around said plurality of laminate sheets,
said plurality of winch assemblies adjusted to tightly hold said
plurality of respective individual straps around said plurality of
laminate sheets.
11. An apparatus for forming and manufacturing a dual radius arch
frame comprising: a horizontally oriented longitudinal member
having an upper surface, a left side region, a center, and right
side region, and plurality of aligned mounting bores laterally
spaced apart in even increments traversing said longitudinal
member; a laterally adjustable support assembly having one end
attached to the center of said longitudinal member in a
perpendicular orientation and a distal end, and further including a
vertical support attached to the distal end, said vertical support
having at least one left strut swivel attach point and at least one
right strut swivel attach point; a left outer form having a
generally semi-circular shaped arch centered and oriented about a
left pivot axis positioned within one of said plurality of mounting
bores located on the left side region of said longitudinal member,
said left outer form having a left cord receiving edge and at least
one left outer form swivel attach point; a right outer form having
a generally semi-circular shaped arch centered and oriented about a
right pivot axis positioned within one of said plurality of
mounting bores located on the right side region of said
longitudinal member, said right outer form having a right cord
receiving edge and at least one right outer form swivel attach
point; an arched shaped center cord section having a left attaching
edge and a right attaching edge, said left attaching edge adapted
to be connected to said left cord receiving edge of said left outer
form and said right attaching edge adapted to be connected to said
right cord receiving edge of said right outer form; at least one
adjustable left strut assembly having a left outer form attaching
end and a left vertical support attaching end, said left outer form
attaching end swivel attached to said one of said at least one left
swivel attach point, and said left vertical support attaching end
swivel attached to at least one left strut swivel attach point; and
at least one adjustable right strut assembly having a right outer
form attaching end and a right vertical support attaching end, said
right outer form attaching end swivel attached to said one of said
at least one right swivel attach point, and said right vertical
support attaching end swivel attached to at least one right strut
swivel attach point.
12. The apparatus according to claim 11, said arched shaped center
cord comprised of a laminate material.
13. The apparatus according to claim 11, further comprising a set
of preformed arched shaped center cords, each center cord having a
different shape, wherein each center cord of said set may be
separately installed into said apparatus to vary the size of the
dual radius arch frame to be formed and manufactured.
14. The apparatus according to claim 12, wherein at least one of a
radius measurement and radial arc length measurement of each cord
may be varied.
15. The apparatus according to claim 11, further comprising a
matching set of preformed left and right outer forms, each matching
set of preformed left and right outer forms having a different
radius, wherein each matching set of preformed left and right outer
forms may be installed into said apparatus to vary the size of the
dual radius arch frame to be manufactured.
16. The apparatus according to claim 11, wherein the dual radius
arch frame is defined a width W, arch height H, span length L and
thickness T.
17. The apparatus according to claim 11, wherein the dual radius
arch frame is defined by a left and right outer form radius defined
by R.sub.4 and wherein said center cord has a radius defined by
R.sub.3 and arc length measurement l.
18. The apparatus according to claim 17 wherein the left and right
pivot axis are equally spaced a distance 1/2L-R.sub.4 from the
centerpoint of said longitudinal member.
19. The apparatus according to claim 11, said at least one
adjustable left and right strut assembly each comprising a strut
member adapted to internally receive a threaded strut member and a
collar having receiving threads for adjusting the length of said
strut assembly.
20. The apparatus according to claim 11, further comprising a
center strut assembly interconnecting said left outer form and said
right outer form.
21. The apparatus according to claim 11, in combination with a
plurality of laminate sheets conformally wrapped around said left
outer form, said center cord, and said right outer form.
22. The apparatus according to claim 11, further comprising a
plurality of winch assemblies attached to said vertical support,
said winch assemblies connected to a plurality of respective
individual straps wrapped around said plurality of laminate sheets,
said plurality of winches adjusted to tightly hold said plurality
of respective individual straps around said plurality of laminate
sheets.
23. A method for forming a dual radius arch frame mounting
structure utilizing a forming apparatus, comprising: establishing a
width W, arch height H, span length L and thickness T of a dual
radius arch frame to be formed; defining the dual radius arch frame
by selecting a left and right outer form radius R.sub.4 and
positioning a left and right outer form having a radius R.sub.4 at
a left and right pivot axis equally spaced a distance 1/2L-R.sub.4
from a centerpoint of a longitudinal member; further defining the
dual radius arch frame by a radius defined by R.sub.3 and arc
length measurement l and positioning a center arch span having a
radius R.sub.3 and arc length measurement l in the forming
apparatus such that the center arch span tangentially interconnects
the left and right forms forming a complete dual radius arch form;
applying a plurality of laminates with adhesive therebetween to the
complete dual radius arch form to form a precut dual radius arch
window frame; surrounding the complete dual arch radius form and
precut dual radius arch frame with a plurality of tensioned straps;
allowing the adhesive to set-up; removing the plurality of
tensioned straps from the forming apparatus; and cutting the dual
radius arch frame along an arch baseline to a desired
dimension.
24. The method according to claim 23 further comprising, utilizing
at least one adjustable left strut assembly and right strut
assembly to interconnect the left and right outer forms,
respectively, to a vertical member laterally offset from the
centerpoint of the longitudinal member and geometrically positioned
underneath the center arch span, to provide additionally bracing to
prevent the deformation or buckling of the complete dual arch
radius form when the straps are applied to the dual radius arch
frame.
25. The method according to claim 23, further comprising utilizing
a center strut assembly to interconnect the left outer form and
right outer form to prevent the deformation or buckling of the
complete dual arch radius form when the straps are applied to the
dual radius arch frame.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] Not Applicable
STATEMENT RE: FEDERALLY SPONSORED RESEARCH/DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to the art of building
construction, and in particular, apparatuses and methods for
forming arched frames that may be utilized in new construction or
in retrofitting or remodeling existing structures. The present
invention is even more particularly applicable to apparatuses and
methods for forming dual radius arched doorway structures, niches
and various interior openings.
[0005] 2. Background of the Invention
[0006] A dual radius arch frame is defined by a generally
horizontal oriented base frame portion and a dual radius arch frame
portion. Referring to FIG. 2, in general, the dual arch radius
frame portion has three sections including a center arch span 10, a
left downwardly curved section 9, and a right downwardly curved
section 11. The center arch span 10 is defined by a first radius
length R.sub.3 having a laterally offset center point 15 which is
geometrically positioned underneath the concave side of the center
arch span 10. The left and right downwardly curved sections 9, 11
are formed from radiuses having a shorter second radius length
R.sub.4. The dual radius arch frame is then formed by tangentially
connecting the left and right sections 9, 11 to the center arch
span 10 at tangents points .tau.L and .tau.R.
[0007] Traditionally, the placement, mounting and peripheral
enclosure of modern, interiorly mounted dual radius arched windows
has heretofore required considerable skill and labor. The
conventional prior art methods of installing dual radius arched
frames required cutting and nailing of short sections of
two-by-four or other wooden material between adjacent wall studs
and under a "header" to roughly approximate a dual radius arched
pattern so as to generally correspond with the desired dual radius
arched shape. The interior drywall or other wall covering material
is then cut according to the dual radius arched shape of the
doorway and nailed over the top of the roughly arranged two-by-four
support sections.
[0008] Provided that the drywall has been correctly cut and
properly placed against the underlying two-by-four support, the
builder must then "fill in" the area between the dual radius arched
edge of the drywall and the frame to create a smooth dual radius
arched jamb such that the jamb will be perpendicular at any given
point to the interior wall surface. The creation of such jamb often
requires the insertion of plywood or other filler materials in an
effort to occupy any void existing between the interior drywall and
the hidden framing. After such void has been filled, plaster or
other appropriate filler materials must then be applied to form the
desired dual radius arched frame surface.
[0009] The above described prior art methods of mounting and
finishing dual radius arched frames are known to be time consuming
and to result in non-uniform and often times uneven interior wall
surfaces. Thus, there exists a need in the art for a simple,
inexpensive and uniformly shaped dual radius arched mounting
structure which may be inserted between the conventional wall
framing and the dual radius arched frame so as to provide a uniform
framing surface.
[0010] One known method to overcome the aforementioned dilemma is
to manufacture a preformed arch as taught in U.S. Pat. No.
4,955,168, entitled "Mounting Structure For Arcuate Window Frames"
to Barry, the subject matter of which is incorporated herein by
reference. Barry teaches a process to manufacture a preformed
arcuate window frame support structure which may be easily
installed into the framing of a building, thus, eliminating the
need to manually form the arched window frame in the traditional
manner. To assist in the manufacture of the preformed arcuate
window frame support structures, Barry teaches applying individual
laminates around an arcuate jig structure and bonding them with
glue which results in a rigid laminated structure having the
desired semi-circular arcuate shape. However, Barry does not
address how to manufacture preformed dual radius arch window frame
supports. Instead, Barry only teaches how to manufacture
semi-circular arches.
[0011] And even if the method taught by Barry is applied to the
manufacture of interior dual radius arch frame mounting structures,
there are other existing challenges indigenous to the manufacture
of dual radius arch preformed window frame supports which are not
experienced in the manufacture of a more basic semi-circular arched
preformed frame support. Mainly, the problem is that dual radius
arch designs may conform to numerous permutations and combinations
of arch size selections, whereas, semi-circular arches only differ
by radius. For instance, the radius of the left and right
downwardly regions 9, 11 may be perhaps 6", 8", 10", 12", 14" and
the center arch span 10 may have a radius of 42", 44", 48", 50",
52" or 54". It is easy to see then, that numerous permutations and
combinations of dual radius arch designs may be generated. A
disadvantage to this process is that an individual jig must be
built for each specific dual radius arch shape. Building various
jigs to meet various standard and custom ordered dual radius shapes
becomes not only time consuming, but is also very expensive.
[0012] In view of the aforestated problems of the prior art, it
would be advantageous to provide a forming apparatus or jig which
may be adjusted to produce a variety of permutations and
combinations of dual radius arch frame mounting structure shapes
without requiring a individualized specific jig for each specific
desired shape of dual radius arch frame mounting structure.
BRIEF SUMMARY OF THE INVENTION
[0013] The present invention overcomes the aforementioned
disadvantages by providing an apparatus and method for forming a
dual radius arch frame. An exemplary embodiment of the apparatus
may include a longitudinal member having a centerline and
centerpoint; a laterally adjustable support having one end attached
to the centerpoint of the longitudinal member in a perpendicular
orientation and a vertical support attached to a distal end of the
laterally adjustable support; a left outer form having a generally
semi-circular shaped arch centered and oriented about a left pivot
axis located on the centerline a predetermined distance from the
centerpoint; a right outer form having a generally semi-circular
shaped arch centered and oriented about a right pivot axis located
on the centerline a predetermined distance from the centerpoint; an
arched shaped center cord adapted to be connected to a receiving
edge of the left outer form and of the right outer form in a
tangentially continuous manner; at least one adjustable left strut
assembly interconnecting the left outer form to said vertical
support; and at least one adjustable right strut assembly
interconnecting the right outer form to the vertical support.
[0014] According to an aspect of the present invention, the present
invention may further include a set of preformed arched shaped
center cords each having a different shape, wherein each center
cord may be separately installed into the apparatus to vary the
size of the dual radius arch frame to be formed. Another aspect of
the present invention allows at least one of a radius measurement
R.sub.3 and arc length measurement l of each cord to be varied. A
further aspect of the present invention includes a matching set of
preformed left and right outer forms, each matching set having a
different radius R.sub.4, wherein each matching set may be
installed into the apparatus to vary the size of the dual radius
arch frame to be formed.
[0015] According to yet another aspect of the present invention,
the dual radius arch frame may be defined by a width W, arch height
H, span length L and thickness T. Additionally, the dual radius
arch frame may be defined by a left and right outer form radius
R.sub.4 and wherein the center cord has a radius R.sub.3 and arc
length measurement l. Moreover, the left and right pivot axis are
equally spaced a distance 1/2L-R.sub.4 from the centerpoint of the
longitudinal member. Another aspect of the present invention
further includes a center strut assembly interconnecting the left
outer form and the right outer form.
[0016] Another aspect of the present invention includes a plurality
of laminate sheets conformally wrapped around the left outer form,
the center cord, and the right outer form. Other aspects of the
present invention include a plurality of winch assemblies attached
to the vertical support, the winch assemblies connected to a
plurality of respective individual straps wrapped around the
plurality of laminate sheets, the plurality of winch assemblies
adjusted to tightly hold the plurality of respective individual
straps around the plurality of laminate sheets.
[0017] Another exemplary embodiment of the present invention is
provided which is an apparatus for forming and manufacturing a dual
radius arch frame. The exemplary apparatus may be composed of a
horizontally oriented longitudinal member having an upper surface,
a left side region, a center, and right side region, and plurality
of aligned mounting bores laterally spaced apart in even increments
traversing said longitudinal member; a laterally adjustable support
assembly having one end attached to the center of the longitudinal
member in a perpendicular orientation and a distal end, and further
including a vertical support attached to the distal end, the
vertical support having at least one left strut swivel attach point
and at least one right strut swivel attach point; a left outer form
having a generally semi-circular shaped arch centered and oriented
about a left pivot axis positioned within one of the plurality of
mounting bores located on the left side region of the longitudinal
member, the left outer form having a left cord receiving edge and
at least one left outer form swivel attach point; a right outer
form having a generally semi-circular shaped arch centered and
oriented about a right pivot axis positioned within one of said
plurality of mounting bores located on the right side region of the
longitudinal member, the right outer form having a right cord
receiving edge and at least one right outer form swivel attach
point; an arched shaped center cord section having a left attaching
edge and a right attaching edge, the left attaching edge adapted to
be connected to the left cord receiving edge of said left outer
form and the right attaching edge adapted to be connected to the
right cord receiving edge of the right outer form; at least one
adjustable left strut assembly having a left outer form attaching
end and a left vertical support attaching end, the left outer form
attaching end swivel attached to one of the at least one left
swivel attach points, and the left vertical support attaching end
swivel attached to at least one left strut swivel attach point; and
at least one adjustable right strut assembly having a right outer
form attaching end and a right vertical support attaching end, the
right outer form attaching end swivel attached to one of the at
least one right swivel attach points, and the right vertical
support attaching end swivel attached to at least one right strut
swivel attach point.
[0018] Another aspect of the instant exemplary embodiment includes
an arched shaped center cord comprised of a laminate material. A
further aspect of the instant invention further includes a set of
preformed arched shaped center cords, each center cord having a
different shape, wherein each center cord of said set may be
separately installed into the apparatus to vary the size of the
dual radius arch frame to be formed and manufactured. Additionally,
at least one of a radius measurement and radial arc length
measurement of each cord may be varied.
[0019] According to an aspect of the present invention, a matching
set of preformed left and right outer forms, each matching set of
preformed left and right outer forms having a different radius,
wherein each matching set of preformed left and right outer forms
may be installed into the apparatus to vary the size of the dual
radius arch frame to be manufactured. Moreover, the dual radius
arch frame is defined by a width W, arch height H, span length L
and thickness, the dual radius arch frame is further defined by a
left and right outer form radius defined by R.sub.4 and wherein the
center cord has a radius defined by R.sub.3 and arc length
measurement l, and the left and right pivot axis are equally spaced
a distance 1/2L-R.sub.4 from the centerpoint of the longitudinal
member.
[0020] Another aspect of the instant embodiment of the present
invention includes at least one adjustable left and right strut
assembly each comprising a strut member adapted to internally
receive a threaded strut member and a collar having receiving
threads for adjusting the length of the strut assembly. Another
aspect of the present invention includes a center strut assembly
interconnecting the left outer form and the right outer form.
Additionally, a plurality of laminate sheets may be conformally
wrapped around the left outer form, said center cord, and the right
outer form. Furthermore, the instant exemplary embodiment may
further include a plurality of winch assemblies attached to the
vertical support, the winch assemblies connected to a plurality of
respective individual straps wrapped around the plurality of
laminate sheets, the plurality of winches adjusted to tightly hold
the plurality of respective individual straps around the plurality
of laminate sheets.
[0021] According to another aspect of the present invention a
method for forming a dual radius arch window frame mounting
structure utilizing a forming apparatus is provided. The method may
include the steps of establishing a width W, arch height H, span
length L and thickness T of a dual radius arch frame to be formed;
defining the dual radius arch frame by selecting a left and right
outer form radius R.sub.4 and positioning a left and right outer
form having a radius R.sub.4 at a left and right pivot axis equally
spaced a distance 1/2L-R.sub.4 from a centerpoint of a longitudinal
member; further defining the dual radius arch frame by a radius
defined by R.sub.3 and arc length measurement l and positioning a
center arch span having a radius R.sub.3 and arc length measurement
l in the forming apparatus such that the center arch span
tangentially interconnects the left and right forms forming a
complete dual radius arch form; applying a plurality of laminates
with adhesive there between to the complete dual radius arch form
to form a dual radius arch frame; surrounding the complete dual
arch radius form and precut dual radius arch frame with a plurality
of tensioned straps; allowing the adhesive to set-up; removing the
plurality of tensioned straps from the forming apparatus; and
cutting the dual radius arch frame along an arch baseline to
provide a finished dual radius arch frame mounting structure.
[0022] The exemplary method of the present invention may also
include utilizing at least one adjustable left strut assembly and
right strut assembly to interconnect the left and right outer
forms, respectively, to a vertical member laterally offset from the
centerpoint of the longitudinal member and geometrically positioned
underneath the center arch span, to provide additionally bracing to
prevent the deformation or buckling of the complete dual arch
radius form when the straps are applied to the dual radius arch
frame. Moreover, the exemplary method may include utilizing a
center strut assembly to interconnect left outer form and right
outer form to prevent the deformation or buckling of the complete
dual arch radius form when the straps are applied to the dual
radius arch frame.
[0023] Other exemplary embodiments and advantages of the present
invention may be ascertained by reviewing the present disclosure
and the accompanying drawings
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The present invention is further described in the detailed
description that follows, by reference to the noted drawings by way
of non-limiting examples of preferred embodiments of the present
invention, in which like reference numerals represent similar parts
throughout several views of the drawings, and in which:
[0025] FIG. 1 depicts an exemplary embodiment of dual radius arch
frame mounting structure;
[0026] FIG. 2 is a notational schematic which depicts geometric
relationships that define a dual radius arch;
[0027] FIG. 3 shows an aspect of a lamination technique utilized to
manufacture a dual radius arch frame mounting structure, according
to an aspect of the present invention;
[0028] FIG. 4 is a cross sectional view taken through line A-A of
FIG. 1;
[0029] FIG. 5 illustrates a dual radius arch installed in an
exemplary doorway structure utilizing a dual radius arched frame
structure, according to an aspect of the present invention;
[0030] FIG. 6A is a top view of an exemplary forming apparatus
utilized to manufacture a dual radius arch frame mounting
structure, according to an aspect of the present invention;
[0031] FIG. 6B is the same view as FIG. 6A, but also shows the
mounting structure formed and strapped to the forming apparatus,
according to an aspect of the present invention;
[0032] FIG. 7A is an upper rear side perspective view of the
forming jig, according to an aspect of the present invention;
[0033] FIG. 7B is the same view as FIG. 7A, but also shows a dual
radius arch frame structure formed and strapped to the forming
apparatus, according to an aspect of the present invention;
[0034] FIG. 8A is an upper front side perspective view of the
forming apparatus, according to an aspect of the present invention;
and
[0035] FIG. 8B is the same view as FIG. 8A, but also shows a dual
radius arch window frame structure formed and strapped to the
forming apparatus, according to an aspect of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0036] The particulars shown herein are by way of example and for
purposes of illustrative discussion of the embodiments of the
present invention only and are presented in the cause of providing
what is believed to be the most useful and readily understood
description of the principles and conceptual aspects of the present
invention. In this regard, no attempt is made to show structural
details of the present invention in more detail than is necessary
for the fundamental understanding of the present invention, the
description taken with the drawings making apparent to those
skilled in the art how the several forms of the present invention
may be embodied in practice.
[0037] The present invention provides an apparatus or jig 5 and
method for forming a dual radius arch mounting structure 2. A
general description of the dual arch radius frame mounting
structure 2 is initially provided. A detailed description of the
forming apparatus or jig 5 is then provided. Finally, a method on
how to utilize the forming apparatus 5 to manufacture the dual
radius arch mounting structure 2 is described.
[0038] General Description of a Dual Radius Arch Mounting
Structure
[0039] FIG. 1 depicts an embodiment of a dual radius arch frame
mounting structure 2. The mounting structure 2 may have a specified
span length L, center arch height H, width W, and thickness T. In
regard to construction, the span length L determines the span
length of the frame and the center arch height H determines the
height of the arched frame. The dual radius arch mounting structure
2 is adapted to provide a conformally fitting arched frame which
provides upper framing structure for doorway structures, niches and
various interior openings. To be able to better appreciate the
present invention, it is first important to understand the
geometric relationships which are present in a dual arch
radius.
[0040] FIG. 2 is a notational schematic which depicts the geometric
relationships that define a dual radius arch. In general, a dual
arch radius has three sections including a center arch span 10,
left downwardly curved section 9, and right downwardly curved
section 11. The center arch span 10 is defined by radius R.sub.3
which has a laterally offset center point 15 and of which is
geometrically positioned underneath the concave side of center arch
span 10. The left and right downwardly curved sections 9, 11 are
formed from radiuses having a shorter radius length R.sub.4 about
left centerpoint 13 and right centerpoint 14. An arch baseline 12,
which represents the bottom of the dual radius arch, intersects the
center points 13, 14 at which the left and right downwardly curved
regions 9, 11 are formed. Each radius furthermore defines tangent
points .tau..sub.L and .tau..sub.R which are the points at which
the center arch span 10 smoothly converges with the left and right
downwardly curved sections 9 and 11. It can be appreciated that a
dual radius arch may have varying shapes. In particular, radius
R.sub.3 and R.sub.4 may each be varied. Thus, numerous permutations
and combinations of R.sub.3 and R.sub.4 may be selected resulting
in various dual arch radius shapes.
[0041] FIG. 3 shows an aspect of a lamination technique utilized to
form a dual radius arch frame mounting structure 2. In particular,
the mounting structure 2 is made from a plurality of individual
laminate sheets 16 that are stacked upon each other, and
furthermore, glued together with a laminate adhesive 17, such as
wood glue or any other adhesive known in the art. The laminate
sheets may have any thickness normally utilized in laminate
manufacturing. For example, the preferred thickness of the laminate
sheet may be 1/8 inch for the exemplary embodiment of the present
invention. The laminate sheet may be made from materials typically
used to manufacture laminate products, for example, wood, fiber
board or particle board to name just a few.
[0042] FIG. 4 is a cross sectional view of the mounting structure 2
taken through cross-section line A-A of FIG. 1. This cross section
shows each individual laminate sheet 16 stacked and glued to each
other forming a rigid board like structure.
[0043] FIG. 5 illustrates an exemplary use of a dual radius arch
frame assembly mounting structure 2. Conventional framing 4
techniques are utilized to frame in the conventional doorway 6,
niche or any other arched structural feature. Also, conventional
framing 4 is installed overhead to mount the dual radius arch frame
mounting structure 2.
[0044] Detailed Description of the Forming Apparatus
[0045] FIGS. 6A, 7A, and 8A illustrate an exemplary embodiment of a
forming apparatus or jig 5 that may be utilized to fabricate a dual
radius arch frame mounting structure 2.
[0046] FIG. 6A is a top view of the forming apparatus 5. The main
components of forming apparatus S may include a longitudinal member
or main jig 36, lateral jig 56, left outer form 18, right outer
form 19, center cord section 21, left adjustable strut assembly 41,
right adjustable assembly 42, vertical support 54, lateral support
58, center strut assembly 70 (see FIG. 6B), and a plurality of
winches 60-63 (see FIG. 6B) and individual straps 64-67.
[0047] The backbone of the forming apparatus 5 is the main jig 36
which is best illustrated in FIG. 6A. The main jig 36 provides a
plurality of generally aligned positional mounting bores 25 which
are adapted to receive left pivot bolt 30, right pivot bolt 33, and
lateral jig bolt 57. The positional mounting bores 25 are
positioned on jig 36 at intervals, for example 1/2 inches apart,
giving the jig 36 the ability to accommodate numerous arch span
lengths L. The mounting bores 25 may be staggered in an upward and
downward pattern to provide sufficient material for the structural
integrity of each bore 25. The main jig 36 is preferably made from
steel. One embodiment of the main jig 36 utilizes a pair of square
tubes with preformed holes spaced every inch. The jig 36 may be
fabricated by positioning the pair of square tubes contiguously
next to each other, offsetting the preformed holes from one tube to
the other by a half interval, and by welding the pair of square
tubes together. Thus, a longitudinal member, or main jig 36, is
formed having mounting bores positioned in an alternating upward
and downward position which allows for 1/2 inch positional
increments.
[0048] The left outer form 18 and right outer form 19 are best
illustrated in FIGS. 6A, 7A and 8A. The left outer form 18
comprises a partial semi-circular left forming arch 22 mounted
upright in a perpendicular manner to a left outer form plate 24.
The left forming arch 22 is centered about a left pivot axis 30
having a radius R.sub.4. The shape of the left outer form plate 24
of the exemplary embodiment conforms to a trapezoidal shape,
however, the shape may vary as long as it performs the same
function. The left outer form plate 24 has numerous functions
including, providing structure for the left pivot axis 30,
providing mounting structure for the left forming arch 22, and
providing structure for securing or attaching devices, such as
C-lamps or vice grips, (not shown or within the scope of the
present invention) to secure and/or attach the left outer form
plate 24 in a rigid stationary position to fixtures (not shown).
Supporting structure 84 may also be provided underneath left outer
form plate 24. For example square steel tubing may be utilized as
the support structure 84. Left outer form plate 24 has a left pivot
hole 80 which is positioned at the left pivot axis 30. A left
receiving edge 86 for receiving the center arched cord section 21
is provided along one of the vertical edges of the left forming
arch 22. On the opposing vertical side of the left forming arm, a
left hinge 38 is provided for pivotally attaching the left swivel
strut member 43. For added rigidity, a left arch brace 23 is
rigidly connected to an upper end of the left forming plate 22 near
the left receiving edge 86 and it spans to the other upper end of
the left forming plate 22 behind the left hinge 38.
[0049] The right outer form 19 is similar to the left outer form
18. In particular, the right outer form 19 comprises a partial
semi-circular right forming arch 26 mounted upright in a
perpendicular manner to a right outer form plate 28. The right
forming arch 26 is centered about a right pivot axis 32 having a
radius R.sub.4. The shape of the right outer form plate 28 of the
exemplary embodiment conforms to a trapezoidal shape, however, the
shape may vary as long as it performs the same function. The right
outer form plate 28 has numerous functions including, providing
structure for the right pivot axis 32, providing mounting structure
for the right forming arch 26, and providing structure for securing
or attaching devices, such as C-lamps or vice grips, (not shown or
within the scope of the present invention) to secure and/or attach
the right outer plate 28 in a rigid stationary position to a
fixture (not shown). Supporting structure 84 may also be provided
underneath right outer form plate 28. For example square steel
tubing may be utilized as the support structure 84. Right outer
form plate 28 has a right pivot hole 82 which is positioned at the
right pivot axis 32. A right receiving edge 88 for receiving the
center arched cord section 21 is provided along one of the vertical
edges of the right forming arch 26. On the opposing vertical side
of the right forming arch 26, a right hinge 40 is provided for
pivotally attaching the right swivel strut member 44. For added
rigidity, a right arch brace 27 is rigidly connected to an upper
end of the right forming plate 26 near the right receiving edge 88
and it spans to the other upper end of the right forming plate 26
behind the right hinge 40.
[0050] It is noted that the radius of both the left forming arch 22
of left outer form 18 and the right forming arch 26 of the right
outer form 19 may be varied according to the desired shape of the
mounting structure 2. For instance, radius R.sub.4 may be 6", 8",
10" or 12" or any other dimension. Therefore, the forming apparatus
may have numerous sets of left and right outer forms 18, 19 for
various production runs depending on the desired shape of the
mounting structure 2.
[0051] FIGS. 6A and 8A best depict the center arched cord section
21. The center arched cord section 21 may be made from a formed
laminate such as particle board, fiber board, plywood or a
fiberglass panel to name just a few materials. The center arched
cord section 21 is representative of the center arch span 10 shown
in FIG. 2. The center arched cord section 21 has left and right
vertical edges which are adapted to be received in left receiving
edge 86 and right receiving edge 88, respectively. The cord section
21 is rigidly attached to each receiving edge 86, 88 by a plurality
of flat head screws or bolts with backing hardware such as nuts and
washers. It is further noted that the radius and size of center
arched section 21 may be varied according to the desired shape of
the mounting structure 2. For instance, radius R.sub.3 may be 44",
48", 50", 52" or 54" or any other dimension. Therefore, the forming
apparatus 5 may have numerous sets of centered arched sections 21
for various production runs depending on the desired shape of the
mounting structure 2.
[0052] The forming apparatus 5 is provided with a left adjustable
strut assembly 41 and a right adjustable strut assembly 42. The
left strut assembly 41 includes left swivel strut member 43, left
threaded strut member 45, left swivel base 47, and left adjustment
collar 46. One end of the left swivel strut member 43 is pivotally
attached to left hinge 38. The other end of left swivel strut
member 43 includes receiving threads to receive the left threaded
strut member 45. Also, the adjustment collar 46 has receiving
threads and is installed on the left threaded strut member 45. So
that strut member 45 is rigidly fixed to an end of left swivel base
47. The other end of the left swivel base 47 is swivel attached to
mounting gusset 52. The result is a left adjustable strut assembly
41 in which the length may be adjusted by rotating the adjustment
collar 46.
[0053] The right strut assembly 42 includes right swivel strut
member 44, right threaded strut member 48, right swivel base 50,
and right adjustment collar 49. One end of the right swivel strut
member 44 is pivotally attached to right hinge 40. The other end of
right swivel strut member 44 includes receiving threads to receive
the right threaded strut member 48. Also, the adjustment collar 49
has receiving threads and is installed on the right threaded strut
member 48. Strut member 48 is rigidly fixed to an end of right
swivel base 50 and the other end of the right swivel base 50 is
swivel attached to mounting gusset 52. The result is a right
adjustable strut assembly 42 in which the length may be adjusted by
rotating the adjustment collar 49.
[0054] Lateral support assembly 51 is best illustrated in FIGS.
6A-B, 7A-B. Lateral support assembly 51 comprises at least lateral
jig 56, lateral strut 58, inclined strut 59, vertical support 54
and mounting gusset 52. In particular, lateral strut 58 and
vertical support 54 are rigidly connected in a perpendicular
orientation. Inclined strut 59 is attached to a mid-portion region
of lateral strut 58 and to an upper mid-portion region of vertical
support 54 at about a forty-five degree angle. Mounting gusset 52
is rigidly attached to an upper end of the vertical support 54 and
is provided with a pair of bores for receiving fastening hardware
for the swivel joints for attaching left swivel base 52 and right
swivel base 50. Lateral jig 56 is mounted perpendicularly to at the
center of main jig 36. The lateral jig 56 is preferably made from
square tubing with preformed holes. Lateral strut 58 is preferably
made from rectangular tubing which has outer dimensions slightly
smaller than the inner dimensions of the lateral jig 56 such that
lateral strut 58 may adjustably and slidably fit within lateral jig
56 with minimal looseness. The insertion end of lateral strut 58 is
disposed with a series of receiving holes for receiving fastening
hardware 57 to secure the insertion end of lateral strut 58 inside
lateral jig 56.
[0055] Additionally, the forming apparatus S may have a plurality
of winch assemblies 60-63 positioned on the vertical support 54.
The exemplary embodiment of the forming apparatus 5 includes four
winch and dual strap assemblies 60, 61, 62, 63 arranged in an
alternating and offset manner about vertical support 54. In
particular, and as best illustrated in FIGS. 7A-B, an upper left
winch assembly 60 is attached on the most upper left hand side of
vertical support 54. On the right hand side of the vertical support
54, an upper right winch assembly 62 is attached at a staggered
height below the upper left winch assembly 60. Then on the left
hand side of vertical support 54, a lower left winch assembly 61 is
attached at a staggered height below the upper right winch assembly
62. And, on the right hand side of the vertical support 54, a lower
right winch assembly 63 is attached at a staggered height below the
lower left winch assembly 61. The winch assemblies 60-63 may
include straps 69 which are adapted to be connected to individual
straps 64-67 which are then wrapped around the entire form and
tightened and/or tensioned when a laminate 16 has been applied to
the form. The operation of the winch assemblies 60-63 and
individual straps 64-67 are discussed in further detail below.
[0056] Method of Utilizing the Forming Apparatus to Manufacture a
Dual Radius Arch Frame Mounting Structure
[0057] 1. Establish Dimensions and Parameters
[0058] A first aspect in manufacturing a dual radius arch frame
mounting structure 2 is to define the desired dimensions or
specifications of the mounting structure 2 to be manufactured. As
previously discussed and illustrated in FIG. 1, the mounting
structure 2 has a specified span length L, center arch height H,
width W, and thickness T.
[0059] The first dimension that should be determined is the span
length L (see FIG. 1). The span length L is typically dependent on
the width of the conventional doorway 6 (see FIG. 5). Next, the
desired arch height H is selected (see FIG. 1). Arch height H is a
parameter which may be based upon personal preference, and
therefore, arch height H may be lower or higher depending on the
style of dual radius arch desired.
[0060] Once the span length L and arch height H are determined, the
shape of the left downwardly curved section 9 and right downwardly
curved section 11 are decided by selecting radius R.sub.4. For
instance, selection of a small R.sub.4 results in a smaller left
and right downwardly curved section 9, 10 and selection of a larger
center arch span section 10 results in a short and flat dual radius
arch. Whereas, utilizing a large R.sub.4 results in a larger left
and right downwardly curved region 9, 10 and a much shorter center
arch span section 10, which results in a more semicircular-shaped
dual radius arch.
[0061] Once R.sub.4 has been selected, R.sub.3, which is also
referred to as the "total rise" of the dual radius arch, may be
determined. R.sub.3 is determined by finding tangent points
.tau..sub.L and .tau..sub.R about the left and right downwardly
curved sections 9, 11 (see FIG. 2). In particular, .tau..sub.L and
.tau..sub.R are the points at which the center arch span 10 meets
the desired arch height requirement H and also tangentially
converges with the left and right downwardly curved sections 9,
11.
[0062] 2. Set-Up Forming Apparatus
[0063] A second aspect in manufacturing a mounting structure 2 is
to set-up forming apparatus or jig 5. With the main parameters of
specified span length L, center arch height H, and radius
parameters R.sub.3 and R.sub.4 determined, the forming apparatus or
jig 5, may be set-up to form the desired dual radius arch window
frame mounting structure 2.
[0064] Initially, a left outer form 18 and right outer form 19 are
selected or fabricated which have a radius equal to the desired
R.sub.4. A distance of half the span length L minus R.sub.4
(1/2L-R.sub.4) determines the distance at which the left and right
pivot axis 30, 32 are positioned on a centerline 12 of the main jig
36. In particular, the distance of 1/2L-R.sub.4 is measured from a
center point of the jig 36. An appropriate positional mounting bore
25 is selected, and fastening hardware is installed into the left
pivot hole 80 and right pivot hole 82 of the left and right outer
forms 18, 19. As a result, the left outer form 18 is rotatably
mounted to the main jig 36 along centerline 12 such that the left
forming arch 22 is tangentially aligned with the left outer
boundary of the span length L. And similarly, the right outer form
19 is then rotatably mounted to the main jig 36 along centerline 12
such that the right forming arch 26 is tangentially aligned with
the right outer boundary of the span length L.
[0065] Once the left and right outer forms 18, 19 are positioned on
the main jig 36, an appropriately sized center arched cord section
21 should be selected or fabricated which has a radius equal to the
desired R.sub.3 and of which has arc measurement of x radians (see
FIG. 2) or arc length l (see FIGS. 2, 6A). The center arched cord
section 21 is then secured to the left receiving edge 86 of the
left outer form 18 and the right receiving edge 88 of the right
outer form 19. The cord section 21 may be rigidly attached to each
receiving edge 86, 88 by a plurality of flat head screw or bolts
with backing hardware such as nuts and washers.
[0066] Another aspect of the set-up process includes positioning
lateral support assembly 51 and the left and right strut assemblies
43, 44. In particular, lateral support assembly 51 may be extended
laterally away from the main jig 36 such that the "total rise"
R.sub.3 dimension is measured between the centered arch cord
section 21 and the center cord axis 34 (see FIG. 6A) or laterally
offset centerpoint 15 (see FIG. 2). Thus, the vertical support 54
is also laterally spaced away from the centered arch cord section
21 by about the same R.sub.3 dimension. Next, the left and right
strut assemblies 43, 44 may be adjusted by rotating the adjustment
collars 46, 49 to either increase or decrease the length of the
left and right strut assemblies 43, 44. The strut assemblies 43, 44
should be adjusted until a firm brace and/or support is provided
between the respective left and right outer forms 18, 19 and the
vertical support member 54. The left and right struts assemblies
43, 44 are utilized to prevent left and right outer forms 18, 19
from buckling inwards when they are under tension by straps
64-67.
[0067] A further aspect of the set-up process includes the
installation of the center strut assembly 70 as shown in FIGS. 6B,
7A-B and 8A-B. Center strut assembly 70 includes center strut
member 76 and center strut member threaded base 74, and threaded
adjustment collar 78. The center strut assembly 70 may be utilized
to provide additional bracing between the left outer form 18 and
the right outer form 19 such that when straps 64-67 are tightened
around the forming apparatus or jig 5, the left outer form 18 and
the right outer form 19 do not buckle inwards. A first mounting
hole 90 is disposed on the distal end of the center strut member 76
to receive fastening hardware which may be fastened to a portion of
the right outer form 19. Furthermore, a second mounting hole 92 is
disposed on the distal end of the center strut member threaded base
74, and is adapted to receive fastening hardware which may be
fastened to a portion of the left outer form 18, such as the left
arch brace 23. By adjusting the threaded center adjustment collar
78, the center strut assembly 70 may be expanded or contracted to
provide a rigid and plum support utilized to prevent left and right
outer forms 18, 19 from buckling inwards when they are under
tension by straps 64-67. After this portion of the set-up is
complete, the forming process of the dual radius arch frame 2 may
begin.
[0068] 3. Applying Laminate Sheets
[0069] As shown in FIG. 3, the forming process of the dual radius
arch frame 2 utilizes a lamination technique. FIG. 6B illustrates
how the laminate sheets 16 are applied and formed around the center
arched cord section 21, left outer form 18, and right outer form
19. It is noted that the length of each individual laminate sheet
16 should be long enough to extend beyond the arch baseline 12. The
laminate sheets 16 and adhesive 17 are applied using lamination
techniques that are known by one of ordinary skill in the art. The
number of laminate sheets 16 utilized to form the dual radius arch
frame 2 may vary depending on the application.
[0070] Once the desired number of laminate sheets 16 have been laid
to form the dual radius arch frame mounting structure 2, straps
64-67 may be connected to shackles 68 disposed on the connecting
ends of winch straps 69 which are adapted to be wrapped within
winch assemblies 60-63. The winch assemblies 60-63 may then be
adjusted such that they are pulled taught against the plurality of
laminates 16 composing the dual radius arch frame 2. After a period
a time has past, the winches 60-63 may be disengaged or loosened
such that straps 64-67 may be removed. The dual radius arch frame 2
may then be removed from the forming apparatus or jig 5. Finally,
the dual radius arch frame 2 may be cut along the arch baseline 12
to desired dimensions.
[0071] Although the invention has been described with reference to
several exemplary embodiments, it is understood that the words that
have been used are words of description and illustration, rather
than words of limitation. Changes may be made within the purview of
the appended claims, as presently stated and as amended, without
departing from the scope and spirit of the invention in its
aspects. Although the invention has been described with reference
to particular means, materials and embodiments, the invention is
not intended to be limited to the particulars disclosed; rather,
the invention extends to all functionally equivalent structures,
methods, and uses such are within the scope of the appended
claims.
* * * * *