NZ535776A

NZ535776A - Arcuate wall construction

Info

Publication number: NZ535776A
Application number: NZ535776A
Authority: NZ
Inventors: Walter Hensch
Original assignee: Hensch Ltd W
Priority date: 2004-10-06
Filing date: 2004-10-06
Publication date: 2005-04-29
Also published as: GB2433751B; GB2433751A; US20080041000A1; AU2005292740A1; WO2006038816A1; GB0706431D0

Abstract

A method of constructing an arcuate wall including stud members and a wall panel member, wherein the method includes the steps of: (i) marking top and bottom plates with markings indicating where the stud members are to be placed, wherein the top and bottom plates have at least a three sided geometric shape with on the sides being arcuate; (ii) placing and fixing the top plate to a first end wall, such as a ceiling or similar end surface; (iii) placing and fixing the bottom plate to a second end wall such as a floor or similar end surface; (iv) aligning and fixing stud members with respect to the markings, to the top and bottom plates so that the stud members extend between the top and bottom plates to form an arcuate wall frame, such that top and bottom edges of a first longitudinal side of the stud members are situated and positioned adjacent to the arcuate edge of the top and bottom plates; (v) aligning a planar wall member to the arcuate wall frame such that the centre of the planar wall member is aligned with the centre of the arcuate wall frame; and (vi) fixing one end of the planar wall member to a corresponding end of the arcuate wall frame and bending the planar wall member around the arcuate wall frame and fixing into place to form the arucate wall.

Description

Patents Form # 5 S3 5 7 NEW ZEALAND Patents Act 1953 COMPLETE SPECIFICATION AFTER PROVISIONAL # : 535776 DATED : 06 October 2004 TITLE : Arcuate Wall Construction We, W Hensch Ltd Address: 21 Willowbank Rd, Tawa, Wellington, New Zealand Nationality: A New Zealand company do hereby declare the invention for which we pray that a patent may be granted to us and the method by which it is to be performed, to be particularly described in and by the following statement: 400062NZ_Cap_20041110_1432_SC.doc FEE CODE 1050 INTELLECTUAL PROPERTY OFFICE OF N.Z. i 0 nov 2004 received ARCUATE WALL CONSTRUCTION Field of Invention This invention relates to an arcuate wall construction, typically the construction of curved or rounded corner walls.

Background of Invention Currently, round corners in the building and design industry are rare as they are complicated to build, especially when wood or wooden products are used as the construction materials.

As a consequence architects tend not to incorporate round corner walls in their designs.

Where the walls are finished with a hard finish other than plaster or drywall, it has often been the practice to construct a curved wall with custom millwork. This custom work, under most circumstances is costly because of the need of skilled labour and the need of custom made panels.

Generally, using previously known methods, the use of plasterboard for curved wall construction has not been suitable due to the tendancy of the plasterboard to break or crack when being bent.

Object of Invention It is an object of the invention to provide a method of constructing an arcuate wall, typically the construction of curved or round walls, that seeks to ameliorate the disadvantages or limitations of the prior art or at least provide the public with a useful choice.

Summary of Invention A first aspect of the invention, resides in a method of constructing an arcuate wall including stud members and a wall panel member, wherein the method includes the steps of: (i) marking top and bottom plates with markings indicating where the stud members are to be placed, wherein the top and bottom plates have at least a three sided geometric shape l:\sadamson\400062nz CS.spec.1104.doc 1 with one of the sides being arcuate; (ii) placing and fixing the top plate to a first end wall, such as a ceiling or similar end surface; (iii) placing and fixing the bottom plate to a second end wall such as a floor or similar end surface; (iv) aligning and fixing stud members with respect to the markings, to the top and bottom plates so that the stud members extend between the top and bottom plates to form an arcuate wall frame, such that a first longitudinal side of the stud members is situated and positioned adjacent to each arcuage edge of the top and bottom plates; (v) aligning a planar wall member to the arcuate wall frame such that the centre of the planar wall member is aligned with the middle of the arcuate wall frame; and (vi) fixing one end of the planar wall member to a corresponding end of the arcuate wall frame and slowly and gradually bending the planar wall member around the arcuate wall frame and fixing into place to form the arcuate wall.

Preferably, the marking of the top and bottom plates is carried out using a template having at least a three sided geometric planar shape with one side that is arcuate, wherein the template has indicia thereon indicating the desired positions for the stud members in order to achieve the arcuate wall frame, wherein use, the template is placed on each of the top and bottom plates such that the top and bottom plates are adapted to be marked in accordance to the indicia on the template.

Preferably, the longitudinal side of the stud members, adjacent the arcuate edge of the base plates, is arcuate.

Preferably, the base plates and stud members are made of wood, metal, plastics or any other suitable material.

Preferably, the planar wall panel is a plasterboard, Gib board, particle board or is made from wood, wood composite, plastic material or any other suitable material.

I:\sadamson\400062nz CS.spec.1104.doc 2 Preferably, the planar wall panel is made from a material capable of being bent.

Preferably, the arcuate wall is adapted to be constructed as part of a vertical wall or horizontal wall.

Preferably, the arcuate wall is adapted to be constructed as part of a corner wall.

Preferably, the arcuate wall is adapted to be constructed as part of a corner between a vertical wall and a horizontal wall.

Preferably, the planar wall panel is fixed to the arcuate wall frame with suitable fastening means such as nails, screws, adhesives, or a combination of nails, screws and adhesives or any other suitable fastening means.

Preferably, the arcuate wall has a % round or lA or % round or full round shape.

Preferably, the fastening means is an adhesive suitable to hold and retain the wall panel in place.

In a second aspect, the invention resides in an arcuate wall, wherein the arcuate wall includes: (i) at least a three sided top base plate having one arcuate side, wherein the top base plate is fixed to a ceiling position or similar upper surface; (ii) at least a three sided bottom plate having one arcuate side, wherein the bottom plate is fixed to a floor portion or similar lower surface; (iii) a plurality of stud members positioned and fixed to the top and bottom plates so as to extend between the top and bottom plates, wherein the stud members are aligned such that a first longitudinal edge of the stud members is in alignment with and adjacent to the edge of the arcuate side of the base plates; (iv) a planar wall panel positioned and fixed to the arcuate sides of each base plate and to the said first longitudinal edge of the stud members.

I:\sadamson\400062nz CS.spec.1104.doc 3 In a third aspect, the invention resides in a template for use in constructing an arcuate wall wherein the template includes: (i) at least a three sided geometric planar shape with one arcuate side, wherein the arcuate side is adapted to determine the contour of the arcuate wall; and (ii) indicia on at least one planar surface of the template, wherein the indicia is adapted to indicate the desired placement of the stud members to form the arcuate wall.

Preferably, the indicia consists of two sets of lines, wherein a first set consists of a plurality of lines that are parallel to one of the non-arcuate side of the template and the second set consists of a plurality of lines that are parallel to the other non-arcuate side of the template, the lines of each set are parallel to and spaced apart from another, wherein the spaced apart distance equates to the width of a stud member.

Any other aspect hereinafter described.

Brief Description of the Drawings A preferred embodiment of the invention will now be described by way of example to the accompanying drawings.

Figure 1 shows a template for use in forming an arcuate wall in accordance to an embodiment of the invention.

Figure 2 shows a base plate in accordance to an embodiment of the invention.

Figure 3 shows a cross-sectional view of an arcuate wall constructed in accordance to an embodiment of the invention.

Figure 4 shows a similar view to figure 3, however in accordance to another embodiment according to the invention.

I:\sadamson\400062nz CS.spec.1104.doc 4 Figures 5 A-D shows examples of arcuate walls in accordance to the invention.

Description of the Drawings Figure 1 shows a preferred form of a template 10 to be used in accordance to the invention. Figure 1 shows a five sided planar shape 10 having four straight sides 12,13,14,15 and one curved side 11. The radius of the curve is preferably 200mm, however other dimensions of radii are possible such as preferably ranging from 100mm to 700mm. Also the template can have three, four or more sides, as long as one of those sides is curved.

The template has two sets of lines. The first set 21,22,23 are parallel to the side 13 and the other set of lines are parallel to side 12 such that the lines of each set are spaced from another a distance equivalent to the width of the stud members to be used so as to define areas in which the stud members are to be placed. In figure 1 there are four such areas shown, 26(a), 27,28, 29, however any number of areas greater than or equal to are envisaged in dependence upon the size of curve (ie radius thereof) and the size (width) of the stud members being used.

The template is preferably made from a thin plastic material or can be made from stiff cardboard or card or even a thin piece of wood or any other suitable material. In use the template is used to mark top and bottom based plates with corresponding lines equivalent to that on the template.

In figure 2 a base plate 30 is shown already marked with markings corresponding to that on the template 10 (Figure 1). The base plate as shown in figure 2 is a three sided geometric figure having two straight sides 31 32 and a third side that is curved 33. As with the template it is envisaged that the base plate can have any number of sides greater than and equal to three as long as one of those sides is curved. The preferred form is of a three sided base plate as shown in figure 2. The base plate 30 is marked with one set of lines 41,42, 43 that are parallel with side 32 and which define stud member receiving areas 47,48. The base plate 30 is further marked with another set of lines 44, 45,46 that are parallel with side 31 and which define further stud member receiving areas 49, 49(a). The stud member receiving areas 47, 48,49,49(a) define the exact positions for the stud members in order to achieve the arcuate wall.

I:\sadamson\400062nz CS.spec.1104.doc 5 Turning to figure 3, there is shown a cross section of an assembled arcuate wall in accordance to an embodiment of the invention. The arcuate wall has stud members 51, 52, 53, 54 positioned and aligned with the respective stud member receiving areas 49(a), 49,48,47 (figure 2). A longitudinal side 51(a) of the stud members is positioned and aligned with the edge of curved side 33 of the base plate 30 such that the longitudinal side 51(a) is adjacent and in alignment with to the curved side 33 as shown in figure 3. A planar wall panel 50 is bent into and fixed into place so that an inner surface of the planar wall panel abuts with the curved side edge 33 and the surface of the longitudinal side 51(a) of the stud member.

A method of construction will now be described with reference to figures 1 to 3. Using the template 10 the top and bottom plates are marked with markings indicating the positions of where the stud members 51, 52, 53, 54 are to be positioned. The top plate is then secured in position on the ceiling or ceiling frame or similar upper surface and the base plate secured in position on the floor or similar lower surface. The base plates can be either screwed, nailed, glued, or a combination thereof, into position. The stud members 51, 52, 53, 54 are aligned and positioned in the respective stud member receiving areas 49(a), 49,48,47 of each base plate such that the stud members extend longitudinally between the two base plates. The stud members are fixed in place by either screws, nails, nail plates, nuts and bolts, or glue or any other suitable fastener. The assembled base plate and stud members forming an arcuate wall frame. A planar wall member, preferably plaster board or Gib board is aligned with the arcuate wall frame such that the centre of the planar wall member 50 is aligned with the middle 33b of the arcuate wall member. The planar wall member 50 is then positioned as shown in dotted lines by the numeral 59(a) such that an end 59(f) of the planar wall member 50 abuts with and is fixed to end 33(a) of arcuate wall frame. The planar wall member 50 is then slowly and gradually bent (positioned 59(b) and 50(c)) to follow the contour of the arcuate wall frame until end 50(e) of the wall frame member abuts with and fixed to end 33(c) of the arcuate wall frame. As the planar wall member 50 is being bent it is fixed to the arcuate wall frame as it comes into contact therewith. The planar wall member can be moistened in order to enhance the bend capabilities thereof. The planar wall member is preferably glued to the arcuate wall frame, however other known fastening methods can be used.

I:\sadamson\400062nz CS.spec.1104.doc 6 Figure 4 is similar to that of figure 3, however it shows another preferred method of attaching the planar wall member 50 to the arcuate wall frame. In this embodiment the planar wall member 50 is first fixed in place at its centre 50(d) to the middle of the arcuate wall frame and then the respective ends 59(e) and 50(f) are rotated towards the respective ends 33(a) and 33(e) of the arcuate wall member so as to bend the planar wall member 50 to follow the contours of the arcuate wall frame.

Figure 5A shows a preferred corner wall construction where the arcuate wall 70 is situated between two vertical side walls 71, 72 and the curvature of the arcuate wall is less than that of the arcuate wall for the corner wall shown in figure 5D.

Figure 5B shows another preferred arcuate wall construction in relation to ceilings. The arcuate wall 74 is constructed and fixed in place between an upper ceiling 75 and a lower ceiling 76. lower ceiling 76 could be replaced with a vertical wall.

Figure 5C shows a further preferred arcuate wall construction where the arcuate wall 77 is situated along a vertical side wall between two side wall panels 78, 79 that are aligned in the same horizontal plane X-X.

Figure 5D shows a similar corner wall construction to that shown in figure 5A, however the curvature of the arcuate wall 80 is somewhat greater.

Advantages ■ able to use known products ■ No need to use pre-formed arcuate wall panels ■ Creates aesthetic appeal ■ Easy to assembly ■ Inexpensive ■ Less labour costs l:\sadamson\400062nz CS.spec.1104.doc 7 Variations Throughout the description of this specification the word "comprise" and variations of that word such as "comprises" and "comprising", are not intended to exclude other additives, components, integers or steps.

It will of course be realized that while the foregoing has been given by way of illustrative example of this invention, all such and other modifications and variations thereto as would be apparent to persons skilled in the art are deemed to fall within the broad scope and ambit of this invention as is herein set forth and as claimed in the appended claim set.

I:\sadamson\400062riz CS.spec.1104.doc 8 WHAT WE CLAIM IS:

Claims

Claim 1: A method of constructing an arcuate wall including stud members and a wall panel member, wherein the method includes the steps of: (i) marking top and bottom plates with markings indicating where the stud members are to be placed, wherein the top and bottom plates have at least a three sided geometric shape with one of the sides being arcuate; (ii) placing and fixing the top plate to a first end wall, such as a ceiling or similar end surface; (iii) placing and fixing the bottom plate to a second end wall such as a floor or similar end surface; (iv) aligning and fixing stud members with respect to the markings, to the top and bottom plates so that the stud members extend between the top and bottom plates to form an arcuate wall frame, such that top and bottom edges of a first longitudinal side of the stud members are situated and positioned adjacent to the arcuate edge of the top and bottom plates; (v) aligning a planar wall member to the arcuate wall frame such that the centre of the planar wall member is aligned with the centre of the arcuate wall frame; and (vi) fixing one end of the planar wall member to a corresponding end of the arcuate wall frame and bending the planar wall member around the arcuate wall frame and fixing into place to form the arcuate wall.
Claim 2: The method as claimed claim 1, wherein the marking of the top and bottom plates is carried out by using a template, wherein the template is at least a three sided geometric planar shape having one side that is arcuate, the template has indicia thereon indicating the desired positions for the stud members in order to achieve the arcuate wall frame such that when in use, the template is placed on each of the top and bottom plates such that the top and bottom plates are able to be marked in accordance to the indicia on the template. G:\400062nz CS.spec.1104.doc 9
Claim 3: The method as claimed in claim 2, wherein the longitudinal sides of the stud members, adjacent the arcuate edge of the base plates, are arcuate in shape.
Claim 4: The method as claimed in claim 3, wherein the base plates and stud members are made of wood, metal, plastics.
Claim 5: The method as claimed in claim 4, wherein the planar wall panel is a plasterboard, Gib board, particle board or is made from wood, wood composite, plastic material or any other suitable material.
Claim 6: The method as claimed in claim 5, wherein the arcuate wall is adapted to be constructed as part of a vertical wall or horizontal wall.
Claim 7: The method as claimed in claim 6, wherein the arcuate wall is a corner wall.
Claim 8: The method as claimed in claim 7, wherein the arcuate wall is part of a corner between a vertical wall and a horizontal wall.
Claim 9: The method as claimed in claim 8, wherein the planar wall panel is adapted to be fixed to the arcuate wall frame with fastening means such as nails, screws, adhesives, or a combination of nails, screws and adhesives or any other suitable fastening means.
Claim 10: The method as claimed in claim 9, wherein the arcuate wall has a lA circular or % circular cross-sectional shape.
Claim 11: The method as claimed in claim 10, wherein the fastening means is an adhesive suitable to hold and retain the wall panel in place.
Claim 12: An arcuate wall, wherein the arcuate wall includes: (i) at least a three sided top base plate having one arcuate side, wherein the top base G:\400062nz CS.spec.1104.doc 10 plate is fixed to a ceiling position or similar upper surface; (ii) at least a three sided bottom plate having one arcuate side, wherein the bottom plate is fixed to a floor portion or similar lower surface; (iii) a plurality of stud members positioned and fixed to the top and bottom plates so as to extend between the top and bottom plates, wherein the stud members are aligned such that a first longitudinal edge of the stud members is in alignment with and adjacent to the edge of the arcuate side of the base plates; and (iv) a planar wall panel positioned and fixed to the arcuate sides of each base plate and to the said first longitudinal edge of the stud members.
Claim 13: The arcuate wall as claimed in claim 12, wherein the positions of the stud members is marked on to top and bottom plates by using a template, wherein the template is at least a three sided geometric planar shape having one side that is arcuate, the template has indicia thereon indicating the desired positions for the stud members in order to achieve the arcuate wall frame such that when in use, the template is placed on each of the top and bottom plates such that the top and bottom plates are marked in accordance to the indicia on the template.
Claim 14: The arcuate wall as claimed in claim 13, wherein the longitudinal sides of the stud members, adjacent the arcuate edge of the base plates, are arcuate in shape.
Claim 15: The arcuate wall as claimed in claim 14, wherein the base plates and stud members are made of wood, metal, plastics.
Claim 16: The arcuate wall as claimed in claim 15, wherein the planar wall panel is a plasterboard, particle board or is made from wood, wood composite, plastic material or any other suitable material.
Claim 17: The arcuate wall as claimed in claim 16, wherein the arcuate wall is adapted to be constructed as part of a vertical wall or horizontal wall.
Claim 18: The arcuate wall as claimed in claim 17, wherein the arcuate wall is a corner wall. G:\400062nz CS.spec.1104.doc 11 'NltLLfcCTUAL PKUPhRTV OFF/CfI OF N.Z. 1 J1 TEC 2004 .received
Claim 19: The arcuate wall as claimed in claim 18, wherein the arcuate wall is part of a corner between a vertical wall and a horizontal wall.
Claim 20: The arcuate wall as claimed in claim 19, wherein the planar wall panel is adapted to be fixed to the arcuate wall frame with fastening means such as nails, screws, adhesives, or a combination of nails, screws and adhesives or any other suitable fastening means.
Claim 21: The arcuate wall as claimed in claim 20, wherein the arcuate wall has a lA round or Vi or % round or full round shape.
Claim 22: The arcuate wall as claimed in claim 21, wherein the fastening means is an adhesive suitable to hold and retain the wall panel in place.
Claim 23: A template for use in constructing an arcuate wall as claimed in either claim 1 or claim 12, wherein the template includes: (i) at least a three sided geometric planar shape with one arcuate side, wherein the arcuate side is adapted to determine the contour of the arcuate wall; and (ii) indicia on at least one planar surface of the template, wherein the indicia is adapted to indicate the desired placement of the stud members to form the arcuate wall.
Claim 24: The template of claim 23, wherein the indicia consists of two sets of lines, wherein a first set consists of a plurality of lines that are parallel to one of the non-arcuate side of the template and the second set consists of a plurality of lines that are parallel to the other non-arcuate side of the template, the lines of each set are parallel to and spaced apart from another, wherein the spaced apart distance equates to the width of a stud member.
Claim 25: A method of constructing an arcuate wall as hereinbefore described with reference to the accompanying drawings G:\400062nz CS.spec.1104.doc 12 WELLECTUAL^PHOPERTY OFFICE! 1 CK 2H» Received
Claim 26: An arcuate wall as hereinbefore described with reference to the accompanying drawings
Claim 27: A template as claimed in claim 23 with reference to figure 1. PIPERS Attorneys for the Applicant END OF CLAIMS G:\400062nzCS.spec.1104.doc 13 INTELLECTUAL PROPERTY OFFICE OF N.Z. * 1 DEC 2004 received