Abstract:
A method and apparatus for construction of an arch is disclosed, having at least one nailing strip or centering element that cooperates with an arch facade assembly to produce an arch. The nailing strip defines a tongue. The arch facade assembly defines a groove. The tongue of the nailing strip matingly engages the groove of the arch facade assembly to be optimally positioned within the opening in which the arch is to be constructed. The facade assembly is secured to the nailing strip to produce at least a portion of the arch.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     The present invention relates to building construction methods and devices. More particularly, the present invention relates to a method and apparatus to form an arch or create an arched opening in a manner that is fast, accurate and produces an aesthetically pleasing appearance. The invention includes a nailing strip that, in conjunction with other elements, facilitates application of the invention to multiple framing environments, including wood, metal and concrete. The nailing strip centers the arch regardless of constant radius, elliptical design or other shapes or configuration. The present invention therefore provides a method and apparatus for framing an arch in various construction environments, including residential, commercial, exterior, interior and other construction applications.  
       DESCRIPTION OF THE PRIOR ART  
       [0002]     The use of arches in building construction is well known. In both residential and commercial settings, an arch doorway, window or other opening adds significantly to the aesthetic quality of the structure. While admittedly desirable, the construction of arched openings has traditionally been a time-consuming project that is, at least in significant part, dependent upon the skill and experience of the builder. In this process, a framer would typically determine the dimensions of the arch to be constructed, measure and cut structural support pieces necessary to frame the opening to the desired dimension, and mount those pieces into place to form an arch or arched opening. The framer would, for example, cut pieces of plywood in accordance with the framed opening, in accordance with previously determined dimensions, and secure the cut plywood pieces to the supporting structural pieces. Obviously, repeating this process for multiple openings, whether doors, windows or otherwise, is a time-consuming process.  
         [0003]     As a result of the skill and time taken to produce such constructions, especially in the residential environment, many arches were poorly built. Many framers had not built a sufficient number of arches to acquire the necessary expertise. Further, the realities of the construction process and environment may and have complicated this process. For example, the opening may not be true, or off-center, or unevenly framed such that the arch support pieces must be adjusted to provide a proper construction. Such realities complicate the framing operation, which can add to the difficulties of an inexperienced framer.  
         [0004]     There have been several attempts in the art to address these difficulties. For example, U.S. Pat. No. 4,400,917 to Mossoro et al. describes an arch perform and method of constructing an arched passageway. The structure includes two substantially identical panels that define the arch, and a third panel that extends between the arcuate edges of the other two panels. The invention is particularly applicable to drywall construction and, as described and claimed, comprises a unitary perform. As a result, while well-suited for this application, the invention may be limited in other environments due to a need for flexibility or use in non-drywall applications.  
         [0005]     Another prior art reference, U.S. Pat. No. 4,601,183 to Hampton, discloses a prefabricated archway that may be sized to fit various framed openings. The invention is described in terms of two full prefabricated archways and form half archways. Two prefabricated half archways may be used in non-standard sized frame openings to increase the width of the arch. The described archway is unitary and defines hollow sections. The archway is installed by nailing through the curved sections into the studs, wall and header, that define the opening. As with other prior art devices, use of this invention may be limited to the specific environment disclosed.  
         [0006]     U.S. Pat. No. 4,665,666 to Hampton discloses and describes a prefabricated archway that is nailed in place directly to the wall and header studs. The archway is made by injection molding and removed from the mold with drywall paper permanently bonded on its exterior surfaces. The drywall paper allows for excellent adhesion of drywall taping compound to the archway. The archway is disclosed in two full prefabricated archways or four half archways. As with the invention of U.S. Pat. No. 4,601,138, use of this invention may be limited to the specific described environment.  
         [0007]     U.S. Pat. No. 4,955,168 discloses and describes a mounting structure for arcuate window frames that is designed to be inserted within an existing wall structure. The outer edge of the mounting structure interfaces with the window frame. The inner edge of the mounting structure is pressed flush against the inner edges of the wall studs. The arcuate frame is formed by multiple wood laminates that may be preformed for use by the framer. The invention is particularly applicable to new building construction, but may be retrofit to existing construction. The invention is readily used to form an arched structure that may be inserted behind an exteriorly mounted window frame to fill in the area between the window frame and the interior drywall.  
         [0008]     U.S. Pat. No. 5,526,618 to Thomas discloses and describes a cased-arch opening kit and method of installation. The kit includes a pair of generally unshaped side columns that are suited for insertion around the terminal edge of a wall, and a curved arch assembly. The curved arch assembly is designed to be sandwiched around the upper wall board that overlies the opening. The curved arch is supported by the generally u-shaped side columns. All three components are secured to the wall structure surrounding the passageway. Thus, the invention described and claimed creates not only an arched opening, but an entire casing of the opening. The invention may be limited to applications where a complete casing of a doorway or similar opening is desired.  
         [0009]     U.S. Pat. No. 6,401,405 to Hicks discloses and describes a method and system for use in forming arched openings. In concrete block construction, the invention contemplates use of a pre-cast and reinforced concrete monolithic header and arched opening. For wood frame construction, and more particularly for non-load-bearing wood frame construction, a lightweight header element may be set within the wall opening so that the top of the arch is substantially horizontal with and slightly below the top of the opening. In the case of wood frame construction where load-bearing capacity is desired, a lintel and arch filler could be formed of stronger materials. The wood-frame apparatus includes laterally downwardly depending appendages. The block construction apparatus includes lower lateral appendages on either side of the arched opening that are supported by the upper surface of the black wall. The disclosed invention thus potentially eliminates for post and beam type headers with an on-side built wooden arch.  
         [0010]     These and other prior art devices and methods each address the need for ready and accurate formation of an arched opening. Even so, there remains a need in the art for a method and apparatus that is readily adapted to various construction environments, and that is readily used by framers of all skill levels. Further, there is a need in the art for an apparatus and method that provides for centering discrete pieces of an arch to insure that the finished product is structurally sound and aesthetically pleasing. Yet further, there is need in the art for an apparatus and method that is flexible in implementation, allowing the framer to adopt the arch to the rigors of various every day construction environments. Thus, the need exists regardless of the type of arch, including semi-circular, equilateral, ogee, tudor or otherwise.  
       BRIEF SUMMARY OF THE INVENTION  
       [0011]     The present invention fulfills the above-described needs, and other needs in the prior art, by providing a method and apparatus for constructing an arch. The present invention may be provided in two symmetrical arch assemblies that, in combination with at least one nailing strip, provide a structurally enhanced and aesthetically pleasing arched opening. It will be appreciated by those of ordinary skill in the art that the present invention is easily adapted to various construction environments, and provides the framer with various options in terms of set-up, attachment and final construction. The present invention further includes a centering element or nailing strip that can be used in block, wood frame or other forms of construction, to properly mount and align the arch assemblies to produce the desired end product. The present invention further provides separate yet mating arch assemblies that cooperate to form an arched opening.  
         [0012]     Generally described, the present invention comprises at least one nailing strip, and an arch section assembly configured for operative attachment to the nailing strip.  
         [0013]     Described somewhat more particularly, the present invention includes a first such assembly comprising a first nailing strip, a second nailing strip and an arch framing assembly. The first nailing strip comprises a raised section immediately adjacent to a mitered edge. The second nailing strip comprises a raised section immediately adjacent to a mitered edge. The arch framing assembly includes two planar arch sections separated one from the other and connected in a substantially parallel configuration to create the forward and rear facade of the final arch construction, the separation of the planar arch sections being configured for mating engagement with the arch attachment sections of the first and second nailing strips.  
         [0014]     In practice of the method of the present invention, an assembly is secured to the frame of an opening. A first nailing strip is secured at the uppermost portion of a wall stud at the desired location of the arch. It will be appreciated by those of ordinary skill that the mitered edge portion of the first nailing strip is positioned at the uppermost end of the first nailing strip. A second nailing strip is then secured to the header of the opening at a substantially right angle to the first nailing strip. Once the two nailing strips are so positioned, the arch facade assembly is secured to the first and second nailing strips to secure the assembly. This operation is performed by placement of the two planar arch sections over the raised tongues of the first and second nailing strips to secure the facade. Once the arch framing or facade assembly is positioned, it may be secured by nail, glue, screw or any suitable means to form the arched opening. The raised tongue sections of the first and second nailing strips receive the attachment device (e.g., nail, screw, glue or other) to secure the arch as desired within the opening. This operation may be repeated for a second mating arch assembly to create the arched opening.  
         [0015]     Thus, it is an object of the present invention to provide an apparatus and method for constructing an arch.  
         [0016]     It is a further object of the present invention to provide an apparatus and method for constructing an arch that can be utilized by a framer of any skill to construct a suitably supported and aesthetically pleasing arch.  
         [0017]     It is a further object of the present invention to provide an apparatus and method for constructing an arch that is readily and quickly adapted to various construction environments.  
         [0018]     It is a further object of the present invention to provide an apparatus and method for constructing an arch that may be readily fit with insulation to provide enhanced construction to a certain wall.  
         [0019]     It is a further object of the present invention to provide an apparatus and method for constructing an arch that may be installed in conjunction with existing framing element, such as windows, regardless of the manufacturer of such existing frame element.  
         [0020]     It is a further object of the present invention to provide an apparatus and method for constructing an arch that provides lateral resistance to a wind load, thereby enhancing the structural soundness of both the arch and the wall within which the arch is constructed.  
         [0021]     These and other objects, features and advantages of the present invention will become apparent and obvious from the following description and the accompanying drawings which are merely illustrative of the invention. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0022]      FIG. 1  is a front elevation of a doorway including an arch constructed according to the apparatus and method of the present invention.  
         [0023]      FIG. 2  is an exploded view of an arch section embodying the method and apparatus of the present invention.  
         [0024]      FIG. 3  is an exploded plan view of an arch section embodying the method and apparatus of the present method.  
         [0025]      FIG. 4  is a plan view of an assembled arch section embodying the method and apparatus of the present method.  
         [0026]      FIG. 5  is a front elevation view showing the arch of the present invention as fitted within a doorway. 
     
    
     DETAILED DESCRIPTION  
       [0027]     The apparatus of the present invention is referred to in the drawings, in which like numerals indicate like parts throughout the several views, generally at  10 . As will be seen, the invention may be employed in exterior or interior construction, residential or commercial settings, and in a variety of environments. For purposes of description only, and not to limit the invention, the invention is described in terms of residential housing.  
         [0028]     Referring to  FIG. 1 , a wall  12  includes and defines a frame  16  which provides a substantially rectangular opening  17  of any dimension. The frame  16  is formed with a pair of vertical studs  18 ,  19  and a header  22 . In conventional manner, drywall panels  24  and  25  cover the vertical studs  18 ,  19  and header  22  to form the wall  12 . Those of ordinary skill in the art will appreciate that the foregoing is traditional in nature and well-known, thus demonstrating the flexibility of the present invention to existing construction. The present invention is also, of course, suitable for new construction. Those of ordinary skill will further appreciate that the configuration of the arched opening is adaptable to the present invention. Thus, the described invention is suited for use with various arch designs such as semicircular, equilateral, ogee, and tudor configurations, to name but a few.  
         [0029]     Referring in yet more detail to  FIG. 1 , an arch  10  according to the present invention is shown. It is to be understood that the arch  10  is preferably comprised of two arch assembles  30 ,  31 . The assemblies  30 ,  31  are substantially identical in construction. Thus, for convenience and without limitation, the following description of arch assembly  30  shall constitute a disclosure of corresponding arch assembly  31 .  
         [0030]     Referring to  FIG. 2 , the arch assembly  30  of the present invention  10  is shown with a first nailing strip (or centering element)  35 , a second nailing strip  40 , and an arch framing facade assembly  50  comprised of a first face  52 , a back face  54 , and the face mount  56 . It is to be understood that the nailing strips  35  and  40  are substantially identical in construction. Accordingly, only one nailing strip  35 , will be described in detail herein. Those of ordinary skill in the art will appreciate that the designation nailing strip is used for convenience, and does not limit the scope of the present invention.  
         [0031]     Referring in detail to  FIGS. 2-4 , nailing strip  35  has a first edge  70  of a leading mitered surface  72 . The mitered surface  72  is preferably provided in a T-shaped configuration with a lower section  72 L, an upper section  72 U, and an edge  76  opposing first edge  70 . The nailing strip  35  further includes a raised portion  77  defined by a top surface  80 , a side surface  81  and another side surface  82 . It will be appreciated that the raised section  77  is defined by indented portion on either side thereof. The dimensions of the indented portion is defined by surfaces  84  and  85  which, as described below, cooperate with the arch face mount  56  to accomplish the present invention. It will be appreciated that the raised section  77  tapers at its trailing portion to a rear edge  88 . It is to be understood that the raised section  77  is of sufficient dimension to receive a nail, screw or any other suitable fastening device to achieve the method and apparatus of the present invention. Thus, it is to be understood that each of the nailing strips  35  and  40  define a raised section  77  that includes a mitered surface  72 , and a pair of opposing indented portions recesses defined in part by surfaces  84  and  85 , and a trailing feathered surface  88 .  
         [0032]     Referring further to  FIGS. 2-4 , the preferred embodiment of the present invention includes a face plate mount  56  that includes a front arch panel  90 , a substantially identical rear panel  92  and a mount assembly  94  disposed between front panels  90   a  and rear panel  92   a . The front panel  90   a  is preferably formed of a sheet material such as plywood. Front panel  90   a  is defined by side edges  96  and  97  and an accurate edge  98 . Similarly, rear panel  92  is defined by side edges  99  and  100  and arcuate edge  101 .  
         [0033]     The face mount assembly  56  is shown in detail in  FIG. 3 . The mount  56  includes two legs  104  and  105  that are connected to or integrally formed with arcuate section  94 . The legs  104 ,  105  and arcuate section  94  are dimensioned to be substantially equal with the raised portion  77  of centering element  35 . The person of ordinary skill will appreciate that panels  90  and  92  are secured to the arch face mount assembly  56  to support the panels  90  and  92  as shown in  FIGS. 2-4 .  
         [0034]     In practice of the present invention, the framer uses the nailing strips  35  and  40  and the arch face mount assembly  56  as follows. The nailing strip  35  is nailed or otherwise secured to the left wall stud  18  at the point of the stud&#39;s intersection with the header  22 . Thus, as shown in  FIG. 1 , the nailing strip  35  is placed against and secured to the uppermost portion of the left stud  18 . Further, the framer secures centering elements  40  to the header  22  by use of nails, screws or any other suitable device. The person of ordinary skill will appreciate that the mitered edges  72  of nailing strips  35  and  40  are positioned to engage and do engage the mitered edges  72 . In this fashion, the nailing strips are secured to the studs  18 ,  19  and the header  22  in such a fashion as to provide raised or extending tongues  77 . To further practice of the preferred embodiment, the face mount assembly  56  is attached to nailing strips  35 ,  40 . The raised tongue  77  of centering elements  35 ,  40  rests between panels  90  and  92  to form one half of the arch as shown in  FIG. 1 . This attachment may be completed in any suitable manner, whether by nails, screws, glue or any other suitable means.  
         [0035]     The person of ordinary skill in the art will appreciate that the arch assembly  31  may be constructed in an identical manner so that the remaining half of the arch  10  is perfected, as shown in  FIG. 1 . Thus, the arch assembly  31  includes a front face  90  and a rear face  92  secured opposite arch assembly  30  with the frame  16 . It should be understood that the panels  90  and  92 , and the face mount assemblies  56 , of arch assemblies  30  and  31 , preferably include feathered or diminishing surfaces so as to utilize the frame  16  as a part of the arch  10 . Thus, for example, at the position indicated by arrow  120  in  FIG. 1 , the header  22  facilitates a consistent arch having an aesthetically pleasing appearance. This arrangement provides a special and unique flexibility for the framer, as the installation of one half  30  of the arch  10  can be performed independently of the other half  31 .  
         [0036]     The dimension of the arch  10  is dictated only by the dimensions of the frame  16  that defines the rough opening. Those of ordinary skill will appreciate that the present invention is not limited to any particular size or configuration of rough opening. As seen above, the raised portion  77  of the nailing strips  35  and  40  are readily configured to facilitate application of the present invention to openings and passageways of various dimension. Those of ordinary skill in the art will appreciate that the present invention has application to not only constant radius or semicircular openings, but also to elliptical openings and other geometric shapes since the nailing strips  35  and  40  may be configured as necessary to match the shape of a given opening. Conventional construction employs standard passageways of 36 inch, 48 inch, 60 inch or 72 inch. Of course, as stated above, the present invention is not limited to any particular rough opening. Thus, by altering the arcuate portion  40  of the arch assembly, arch assemblies of varying configuration may be readily constructed for 36 inch, 48 inch, 60 inch or 72 inch wide passageways. The invention  10  may be installed using a variety of different tools or suitable other devices. For example, the arch assembly may be formed using nails, screws, glue or other fasteners. Once configured, the arch assembly may be placed and secured to the nailing strips using any suitable mechanism, including nails, screws, glue or otherwise. Of course, as the dimension or shape of the opening changes, the dimension of the nailing strips  35  and  40  and the facade assembly  50  changes accordingly. So, if the opening is elliptical, the nailing strips  35  and  40  are configured to fit the dimension of the elliptical opening. Such dimensional changes are considered to be well within the skill of one of ordinary skill, and need not be disclosed in further detail herein.  
         [0037]     It will be appreciated that proper positioning of the invention  10  is ascertained when the lowermost ends of the arch assemblies engage the sides of the passageway and the mid-point of the arch is to be ultimately centered at the uppermost portion of the opening or passageway. To accomplish this, the arch component (such as  90 ) is constructed to terminate slightly before the center of the opening or passageway so that the builder is not required to alter the rough opening that may be required by the manufacturer of accompanying door or window framing. The radius created by the arch may be construed as that the two halves taper to nothing at this centerpoint. However, since the frames cannot typically achieve this perfect taper of both halves, stopping the arch component  90  just short of the centerline allows the device to be used even in an opening that may be narrowly constructed. Such a construction also insures the integrity of the arch elements, insuring that none are too fine or small for handling, slipping, etc. Thus, the preferred taper reaches to approximately one-quarter of an inch (¼″) to minimize any damage during shipping and handling. If the wall portions are properly framed, the arch assembly will be relatively easily fit to the proper position. However, because such framing elements as the wall studs  18 ,  19  and the header  22  are often out of alignment or the rough opening is out of square, manipulation of the arch assemblies on the centering element tongues  77  allows for the resulting arch  10  to be fit appropriately within the passageway  17 .  
         [0038]     It is thus seen that the present invention provides an efficient and economical method and apparatus for the construction of an arch. Accordingly, the invention meets the objects described above. While the preferred embodiments of this invention have been set forth for the purposes of disclosure, including the best mode of practicing the invention, those of ordinary skill in the art will appreciate that other embodiments may be made and practiced within the spirit and scope of the present invention.