Static structures (e.g. – buildings) – Vertically curved arch with terminal support – Monolithic arch
Reexamination Certificate
2000-01-19
2002-06-11
Friedman, Carl D. (Department: 3635)
Static structures (e.g., buildings)
Vertically curved arch with terminal support
Monolithic arch
C052S086000, C052S211000, C052S745070
Reexamination Certificate
active
06401405
ABSTRACT:
BACKGROUND
1. Field of Invention
The present invention relates to materials and methods used in building construction to make arched-shaped openings, specifically to a method and system for use in forming arched openings in both concrete block and wood frame building construction. The materials from which it was made would determine its load bearing capacity. Applications may include, but are not limited to, use in more rapidly and easily forming a window opening with an arched upper perimeter in both residential and commercial construction.
2. Description of Prior Art
In recent construction of both residential and commercial buildings, one can see the increasing popularity of building designs having windows and doors with an arched upper perimeter. They add an aesthetically pleasing and architecturally sophisticated look to a building. However, to make the openings for installation of such windows and doors. plywood and 2×4's are commonly used to form the concavely configured upper perimeter and such structures are commonly built on site. The disadvantage of this prior art method is that it is time consuming. A framer would have to refer to the radius of curvature of the window or door intended for installation and accordingly measure and cut several structural 2×4 pieces of wood having incremental differences in length. Once a standard rectangular window or door frame was constructed around a wall opening of sufficient height to accommodate installation of the intended arched window or door. the shortest 2×4 pieces of wood would then be attached centrally to the upper perimeter of the standard frame so as to downwardly and perpendicularly depend therefrom. Thereafter, in succession the incrementally longer 2×4 pieces of wood would be placed at spaced-apart distances from the shortest 2×4 piece or pieces of wood and also attached to the standard frame so as to also downwardly and perpendicularly depend therefrom. Referring again to the radius of curvature of the window or door intended for installation, the framer would then measure and cut two pieces of plywood each with one concavely arcuate perimeter edge having a radius of curvature identical to that of the window or door intended for installation within the wall opening. The cut plywood pieces would then each he oriented with its arcuate perimeter edge facing the center of the wall opening and secured within the inside perimeter of the standard frame to each of the 2×4 pieces attached to the upper perimeter of the standard frame. When the above cutting, measuring and attaching steps are repeated for the installation of even a few arched windows and doors used in a building design, the total time required to perform the extra framing steps for the arched windows and doors becomes significant.
The method of the present invention contemplates the use of monolithic pre-cast arched concrete headers in block construction. as well as the use of pre-formed arches in wood frame construction that could be made from recycled plastic attached to or including a lintel. Installation time for each pre-formed arch is estimated to be as little as five minutes. Use of the method disclosed in the present invention would eliminate the need for post and beam type headers with a site-built wooden arch and thereby reduce the amount of labor required on a job site to install windows and doors having an arched upper perimeter. Where load bearing capacity is required, the method of the present invention accounts for such needs. In addition to having a labor saving advantage, the method of the present invention also reduces construction site cost by eliminating the material waste associated with materials that are incorrectly measured and cut on a job site. Although it is known to have interconnecting structural panels each having a top load-carrying header plate to erect a load bearing wall, devices used to support a masonry arch during construction, and prefabricated concrete slabs which can be vertically positioned within an elongated ground trench and connected to form a building structure, as well as apparatus for molding prefabricated concrete sections on site for use in the construction of vaulted structures such as culverts and tunnels, it is not known to have a method and system for using monolithic pre-formed structures for the installation of arched windows and doors that has all of the advantages of the present invention.
SUMMARY OF INVENTION—OBJECTS AND ADVANTAGES
It is the primary object of this invention to provide a time saving method for installing arched windows and doors in residential and commercial construction. It is a further object of this invention to provide a cost reducing method for installing arched windows and doors in residential and commercial construction. It is also an object of this invention to provide a monolithic pre-formed header and arch opening in standard sizes that can be easily transported to a construction site and easily handled during installation into standard sizes of rectangularly framed window and door openings. A further object of this invention is to provide monolithic pre-formed header and arch openings for custom work involving non-standard sizes of windows and doors. It is also an object of this invention to provide a monolithic pre-formed header and arch opening that is made from plant pre-cast and reinforced concrete so as to be load bearing. It is a further object of this invention to provide monolithic pre-formed header and arch openings that are not load bearing. A further object of this invention is to provide pre-formed arched structures for wood frame construction that are not load bearing and made at least in part from recycled plastic.
As described herein, properly manufactured and used to install arched windows and doors within framed rectangular openings in block and wood frame structures, the method and system of the present invention would provide a means for more rapid and cost efficient on-site installation of the arched windows and doors than is currently possible with the commonly used method of site-built arches made from plywood and 2×4's. The present invention can be configured for installing standardize size arched windows and doors, as well as the nonstandard sizes needed for custom work. In block construction the present invention contemplates the use of a plant pre-cast and reinforced concrete monolithic header and arched opening combination for each arched window or doorway incorporated into a building design, which after manufacture is transported to a job site, set upon the exposed upper surfaces of blocks positioned on opposite sides of the wall opening to create the intended arched window or doorway configuration. and thereafter attached directly to the block adjacent to the upper portion of the window or doorway opening with mortar and/or mortar in combination with other attachment means. When attached in its usable position, the top of the monolithic header and arched opening combination is approximately level with the top of the wall opening. In setting each pre-cast monolithic header and arched opening combination upon the upper surface of blocks on both sides of a wall opening, a near seamless and uniformly concave upper perimeter is formed within the wall opening. Since the concrete header and arched opening combination is monolithic. it is load bearing and provides strong support for the wall structure above the window or doorway opening. and it can be readily and easily connected to adjacent block with mortar. In addition it is contemplated for the pre-cast concrete header and arched opening combinations to have a central upper groove extending longitudinally the entire length of its upper surface. at least one reinforced steel rod or bar positioned below the upper groove and extending longitudinally the entire length of the concrete header and arched opening combination, and at least one second groove positioned within the upper surface of the concrete header and arched opening combination which inters
Friedman Carl D.
Morse Dorothy S.
Thissell Jennifer I.
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