Patent Publication Number: US-10780483-B1

Title: Curving tool for wall and ceiling framing members

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to U.S. Provisional Patent Application Ser. No. 62/322,829, filed on Apr. 15, 2016 and entitled “CURVING TOOL FOR WALL AND CEILING FRAMING MEMBERS”, the content of which being incorporated herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to wall and ceiling framing members for the construction industry, and more particularly to a tool for shaping such wall and ceiling framing members, as well as methods for shaping the wall and ceiling framing members using such tool. 
     BACKGROUND OF THE INVENTION 
     Walls and ceilings are often constructed upon a frame that is made up of a plurality of individual framing members which are connected to establish the desired wall or ceiling configuration. Commercial and industrial construction projects typically utilize metal framing members for a variety of reasons. One particular advantage of metal framing members over wood counterparts is the ability to easily shape metal framing members to form non-standard wall and ceiling configurations. In particular, walls and ceilings that exhibit curvature may be most easily constructed with the use of non-linear metal framing members. 
     Some relatively large scale construction projects obtain the metal framing members in a “pre-curved” configuration, wherein a set of framing members are individually precisely curved by specialized equipment prior to delivery to the construction site. For other projects, however, framing installers are required to establish framing member curvature on-site. While some tools and techniques have been developed in the past to address this need for framing installers to perform rapid shaping of metal framing members on-site, the currently available solutions fail to provide a reliable mechanism for creating accurate curves into wall and ceiling framing members. It is therefore an object of the present invention to provide a tool that is straightforward for use by a framing installer, and is capable of creating consistent and accurate curves to the framing members. 
     SUMMARY OF THE INVENTION 
     By means of the present invention, wall and ceiling framing members may be conveniently and accurately shaped with curves or bends, including accurately producing predetermined curvature radii. The members envisioned for use with the present invention include wall or ceiling channels which support the ends of members extending between the channels, as well as such members extending between the channels. 
     In one embodiment, a tool for shaping wall and ceiling framing members includes a frame having a base and first and second walls connected to the base and defining a length between the first and second walls. The first wall terminates at a first end to define a first height with respect to the base, and the second wall terminates at a second end to define a second height with respect to the base. The tool further includes a plate that is positioned between the first and second walls, and is pivotally secured to the frame about a pivot axis, wherein the plate has a lower surface facing the base, and an opposed upper surface. The tool has an edge movable with the plate and oriented substantially transverse to the first direction within the length. An adjustment member is engaged with the plate, and is arranged to adjust a pivot orientation of the plate about the pivot axis, wherein the edge is positionable upwardly from a first plane connecting the first and second ends of the first and second walls. 
     In another embodiment, a tool for shaping wall and ceiling framing members includes a housing having a base with a perimeter defining first and second sides, a first wall extending upwardly from the first side and terminating at a first end to define a first height with respect to the base, and a second wall extending upwardly from the second side and terminating at a second end to define a second height with respect to the base. The tool further includes a plate that is connected to the housing, and an adjustment mechanism for selectively adjusting a position of the plate with respect to the base. A fulcrum is repositionable with the plate to a location wherein a first plane connecting the first and second ends of the first and second walls is between the fulcrum and the base. 
     A method for shaping a wall or ceiling framing member includes providing a tool as described above, and placing a first portion of the wall or ceiling framing member at the first end of the first wall of the tool. A second portion of a wall or ceiling framing member is then placed at the edge of the tool. A wall or ceiling framing member is then bent about the edge of the tool. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a top perspective view of the apparatus of the present invention; 
         FIG. 2  is a top plan view of the apparatus of the present invention; 
         FIG. 3  is a side elevational view of the apparatus of the present invention with a portion removed from view; 
         FIG. 4  is a cross-sectional side view of the apparatus of the present invention; 
         FIG. 5  is a perspective view of the apparatus of the present invention with a workpiece; 
         FIG. 6  is a perspective view of the apparatus of the present invention with a workpiece being shaped; 
         FIG. 7  is a perspective view of the apparatus of the present invention with a workpiece being shaped; 
         FIG. 8  is a side elevational view of the apparatus of the present invention with a workpiece being shaped; 
         FIG. 9  is a side elevational view of the apparatus of the present invention with a workpiece being shaped; 
         FIG. 10  is a side elevational view of the apparatus of the present invention with a workpiece being shaped; and 
         FIG. 11  is a side elevational view of the apparatus of the present invention with a workpiece being shaped. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     The objects and advantages enumerated above together with other objects, features, and advances represented by the present invention will now be presented in terms of detailed embodiments described with reference to the attached drawing figures which are intended to be representative of various possible configurations of the invention. Other embodiments and aspects of the invention are recognized as being within the grasp of those having ordinary skill in the art. 
     Unless otherwise apparent or stated, directional references, such as “upper”, “lower”, “interior”, “exterior”, “top”, “bottom”, “vertical”, “horizontal”, “upward”, “downward”, and the like are intended to be relative to the orientation of a particular embodiment of the invention as shown in the figures. In addition, a given reference numeral in the drawings indicates the same or similar structure when it appears in different figures and like reference numerals identify similar structural elements and/or features of the subject invention. 
     With reference now to the drawing figures, and first to  FIG. 1 , tool  10  includes a housing or frame  12  with a base  14  and first and second walls  16 ,  18  connected to the base  14 . Base  14  may have a perimeter  20  defining at least a first side  22  and a second side  24 , wherein first wall  16  may extend upwardly from first side  22  of perimeter  20 , and second wall  18  may extend upwardly from second side  24  of perimeter  20 . It is contemplated, however, that at least one of first and second walls  16 ,  18  may be connected to one or more portions of base  14  other than, or excluding perimeter  20 . In the illustrated embodiment, first and second walls  16 ,  18  extend from respective first and second sides  22 ,  24  of perimeter  20 , and define a length “L” along a first direction  26  between first and second walls  16 ,  18 . In typical embodiments, length “L” in the range of between about 4-30 inches, though it is contemplated that such dimensional range may be expanded to accommodate various applications for tool  10 . 
     In the illustrated embodiment, housing or frame  12  includes third and fourth walls  28 ,  30  connected to base  14 , first wall  16 , and second wall  18  to form a partial enclosure  32 . One or more of walls  16 ,  18 ,  28 ,  30  may be integrally formed with and extend directly from base  14 , or may instead be connected directly or indirectly to base  14  through fasteners, adhesives, and the like. The components of frame  12  may be fabricated from any suitable material, though various metal materials are contemplated as being most likely employed in the manufacture of frame  12 , with particular examples including aluminum, nickel steel, galvanized steel, stainless steel, and other relatively strong and durable metal materials. 
     Base  14  includes an upper surface  15  such that, for the purposes hereof, the term “upward” or “upwardly” shall mean generally along direction  34 . 
     First wall  16  may extend upwardly from base  14 , and may terminate at a first end  36  to define a first height “h 1 ” with respect to base  14 . Second wall  18  may extend generally upwardly along direction  34  from base  14 , and may terminate at a second end  38  to define a second height “h 2 ” with respect to base  14 . In some embodiments, first and second heights h 1 , h 2  may be substantially equal. In other embodiments, however, such first and second heights h 1 , h 2  may be inequal. In typical embodiments, first and second heights h 1 , h 2  may be in the range of between about 1-10 inches, though it is contemplated that such dimensional range may be expanded to accommodate various applications for tool  10 . 
     In the illustrated embodiment, first and second walls  16 ,  18  are substantially parallel to one another, though it is contemplated that such first and second walls  16 ,  18  may be skew with respect to one another. 
     In some embodiments, a plurality of spaced apart projections  40  may be connected to at least one of first and second ends  36 ,  38  of the respective first and second walls  16 ,  18 . Such spaced apart projections may extend at an angle that is less than 180° from a respective one of the first and second ends  36 ,  38 , and, as shown in the illustrated embodiment, toward the other of the first and second ends  36 ,  38 . In some cases, projections  40  extend at an approximately 90° angle with respect to the associated one of the first and second walls  16 ,  18  toward the other of the first and second walls  16 ,  18 . Such an arrangement is illustrated in the drawings. 
     As will be described further hereinbelow, projections  40 , and particularly gaps  42  between adjacent projections may be arranged to receive portions of the wall and ceiling framing members shaped through the use of tool  10 . One or more portions of a wall or ceiling framing member, for example, may be received in one or more gaps  42  between adjacent projections  40  so that an adjacent portion of such wall or ceiling framing member may bear against the surface of projection  40  to hold the wall or ceiling framing member in place during a shaping process. Projections  40  may be provided in one or more of a variety of configurations, and therefore define gaps  42  of various configuration. 
     In the illustrated embodiment, projections  40  may exhibit a parallelepiped body extending from a respective first or second end  36 ,  28 . The projections  40 , however, may be somewhat modified in their parallelepiped configuration, with rounded corners and/or edges. As such, applicants&#39; consider the illustrated form of projections  40  to be “substantially parallelepiped”. 
     Tool  10  preferably further includes a plate  50  that is connected to the housing or frame  12  and positioned between first and second walls  16 ,  18 . In the illustrated embodiment, plate  50  is pivotally secured to frame  12  about a pivot axis  52 , which may be defined by a shaft  54  connected to third and fourth walls  28 ,  30 . Plate  50  may include one or more sockets  56  with a receptacle  58  for receiving shaft  54  along pivot axis  52 . Sockets  56  may be integrally formed with, or connected to plate  50 . In the illustrated embodiment, plate  50  has a lower surface  60  facing base  14 , and an opposed upper surface  62 . 
     An adjustment mechanism  64  is provided for selectively adjusting the position of plate  50  with respect to base  14 . In the illustrated embodiment, adjustment member  64  may be engaged with plate  50 , and arranged to adjust a pivot orientation of plate  50  about pivot axis  52 . It is contemplated that adjustment mechanism  64  may selectively adjust the position of plate  50  in a variety of ways, though it may be advantageous to provide adjustment mechanism  64  with the ability to make minor adjustments to the position and/or orientation of plate  50 . 
     In the illustrated embodiment, adjustment mechanism  64  is threadably adjustable, in that rotation of a threaded shaft  66  with a fixed threaded engagement alters the position of plate  50  with respect to base  14 . Threaded shaft  66  may be threadably engaged with an engagement portion  68  that is fixedly connected to plate  50 , so that rotation of threaded shaft  66  with respect to engagement portion  68  results in axial movement of plate  50  along shaft  66 . Base  14  may provide a bearing surface against which threaded shaft  66  may contact to support and adjust the position of plate  50 . A handle  70  may be provided to assist in the rotation of threaded shaft  66 , wherein handle  70  is connected to threaded shaft  66 . 
     An edge  72  is repositionable with plate  50  to a location wherein a first plane  74  connecting first and second ends  36 ,  38  of first and second walls  16 ,  18  is between edge  72  and base  14 . Edge  72  may be movable with plate  50  and oriented substantially transverse to first direction  26  within length “L”. For the purposes hereof, to be “within length L′” means between respective wall planes  80 ,  82  that are perpendicular to base  14  and tangential to respective first and second ends  36 ,  38 . For the purposes hereof, the term “edge” means a narrow portion at or adjacent to the beginning or end of an object or object feature. The object may be a blade  76 , as illustrated in the drawings. In other embodiments, edge  72  may be formed from plate  50 , as the narrowed end of a feature formed into plate  50 . In the illustrated embodiment, blade  76  may be connected to plate  50 , and may extend in an upward direction with respect to upper surface  62  of plate  50 . Blade  76  may be variously shaped as a protrusion from or connected to plate  50 . 
     Tool  10  may be used alone or in connection with a platform  90 , wherein tool  10  may be secured to platform  90  through a variety of means, including fasteners extending through apertures  13  in base  14 . As shown in  FIGS. 5-11 , a wall or ceiling framing member  92 , which may be referred to herein as a “workpiece” may be shaped by bending the workpiece  92  about edge  72 . The relative adjustable position of edge  72  with respect to first plane  74  may determine the extent of bending or curving applied to the workpiece. So that the shaping may be performed to a consistent and predictable extent, a first portion  94  of workpiece  92  may be placed at first end  36  of first wall  16 , and a second portion  96  of workpiece  92  placed at edge  72 . When so positioned, the workpiece is bent about edge  72  to impart a desired shaping to workpiece  92 . 
     Edge  72  preferably represents a fulcrum about which the workpiece may be shaped to a desired extent, with such extent determined by a combination of length “L” and the relationship between the fulcrum and first plane  74 . Consistent and accurate shaping of the workpiece may be enabled by bending the workpiece about the fulcrum until a third portion  98  of workpiece  92  contacts second end  38  of second wall  18 . Thus, where both the length “L” and a fulcrum height “F” above first plane  74  are known, the radius of curvature applied to such workpiece  92  may be calculated. 
     Workpiece  92  may preferably be fabricated from a material that may be permanently deformed with an applied physical stress without breaking. Therefore, workpiece  92  may preferably exhibit sufficient plasticity, ductility, and malleability to be modified in its configuration through the process described herein without either breaking or substantially rebounding toward its original configuration. Most commonly, workpiece  92  may be fabricated from a relatively light-gauge steel, such as between 16-22 gauge sheet steel. Contacting third portion  98  of workpiece  92  to second end  38  may therefore preferably permanently alter the configuration of workpiece  92  to a desired shape. Adjusting the position of the fulcrum with adjustment mechanism  64  may set edge  72  into a predetermined location with respect to first and second ends  36 ,  38  and first plane  74 . Such relative location of the fulcrum provides the accurate extent of shaping to workpiece  92 . 
     Depending upon the configuration for workpiece  92 , first portion  94  of workpiece  92  may be engaged with one or more of projections  40  by receiving first portion  94  of workpiece  92  into one or more of gaps  42 . When so engaged, application of a force to workpiece  92  to bend workpiece  92  about the fulcrum represented by edge  72  causes first portion  94  to be restrained by one or more of projections  40 . Such restraint aids in securing workpiece  92  to at least first end  36  of tool  10  during the shaping process. First portion  94  of workpiece  92  need not be an end of workpiece  92 . Instead, second portion  96  is merely between first portion  94  and third portion  98 . 
     Workpiece  92  may be “pre-creased” by having crimps or creases placed in one or more portions thereof. In some embodiments, such creases may align with the fulcrum of edge  72  during the shaping process, so that edge  72  may nest into the crease to support workpiece  92  in the shaping process. In other embodiments, however, it is contemplated that workpiece  92  may not have crimps or creases, and that the fulcrum may not contact workpiece  92  at a pre-formed crimp or crease. 
     The invention has been described herein in considerable detail in order to comply with the patent statutes, and to provide this skilled in the art with the information needed to apply the novel principles and to construct and use embodiments of the invention as required. However, it is to be understood that the invention can be carried out by different methods/devices, and that various modifications can be accomplished without departing from the scope of the invention itself.