US2303003A - Method of forming fabricated walls - Google Patents

Description

Nov; 24; 1942. w, EQRUMSEY 2,303,003

METHOD OF FORMING FABRICATED WALLS Filed March 13, 1940- 2 Sheets-Sheet 1 Patented Na 24, 1942' 3 UNITED STATES:

METHOD OF FORMING ranarca'mn WALLS- Walker 1;. Ramsey, vitamin, Application Mmhia, 1040, Serial no." mm

7 (Cl. 20'4i.5)

This invention. relates to the construction of walls, and the present specification describes the invention as applied to the construction of walls for moving picture sets. The walls of moving picture sets are usually constructed of plywood secured to rigid frames constructed by carpen-,

' ters. *Unless the plywood is of considerable thickness it isquite readily vibrated, and sometimes acts as a resonant sounding-board that may interfere with technically correct reproduction of sounds occurring on the stage of the set.

= When it is necessary to form a curved wall for a set, it. is necessary for the carpenters to construct a frame with a considerable number ofsupports for the rear side of the curved wall in order to give suiiiicent rigidity to the structure, and to overcome any -tendencies to develop vibrations and resonance in the wall. On this account it is highly desirable that a moving picture set should have natural rigidity sufl'icient,

to insure, for example, that when a door in'a wall is slammed, no vibration will be apparent in the moving picture.

One of the objects ofthe present invention is to provide a simple method and apparatus for facilitating the contsruction of moving picture sets, and particularly those involving the use of curved walls.

A further object of the invention is to provide which will have natural rigidity due to the manner in which the same are fabricated.

A further object of the invention is to provide a simple method for making a rigid cursed wall without the necessity for employing clamps or other means for exerting pressure between the layers of material that are being secured together to form the wall.

structureare broken away. I Fig.-2 is a view similar to Fig. 1-,butlessex set constructed in accordance with my method,- and illustrating in section a portion of the ap'- paratus which I prefer to employ'for accomplishing thepurposes of this invention. In this view portions of the apparatus and fabricated tensive and of a more or less diagrammatic I nature. This view particularly illustrates steps in the method employed in constructing a set that is to present its concave face to the camera.

Fig. 3 is a perspective illustrating a portion 3 of a curved fabricated set constructed in accordance with my invention, and in which the convex face is to be exposed to the camera.

Fig. 4 is a horizontal sectionthrough a portion of a wall such as could be used for a .mov-

ing picture set constructed in accordance with my invention, and including a curved portion,

' illustrated in F18. 5.

a simple method for constructing curved walls,

A further object of the invention is to provide a simple method for forming fabricated walls for curved moving picture sets, which will be relativeiy inexpensive as compared with the present methods of constructing the same, and which will be substantially unaffected. by sound and vibrationless from sounds produced on the stage, or in its vicinity. L

Further objects of the invention will appear hereinafter.

The invention consists in the novel acts and.

the concave side of which is to be exposed to the camera. I

Fig. 5 is aplan view of the platen and other apparatus employed therewith for constructing moving picture sets in accordance with my method. .In-this view a portion of the platen sheet is broken away so as to expose the trans- .sheet. material is supported with the concave side uppermost. The material I prefer to em ploy is preferably of a porous composition'such as Insulite, or similar material. This material is quite flexible, and when supported on a curved bed or sheet, will readily assume the form of the supporting sheet or-plate. The sheet 'takes its shape by gravity on the bedor' plate. On this bottom layer or sheet I apply an adhesive or cement-over which I apply the second sheet of combination of acts to be'described hereinafter,

all of which contribute to produce an emcient method of fabricating a moving picture set.

In the drawings; Fig. .l is. a vertical section taken through a the v material being employed, such as Insulite. In this way the method may be proceeded with to produce a wall of any desired thickness. The

rigidity of this wall is derived from the fact that the layers, while holding themselvesin a curved condition, are secured together. By, reason of I this inherent rigidity in this fabricated structure, it is unnecessary to build a frame. onwhich partially formed curved wall for a moving picture the wall material is applied, and which-will give a PATENT sea-ice words, it is merely necessary to attach the fabricated wall to a light frame, providing a foot or base that will facilitate its being handled on and off of the set, and without necessitating the workmens placing their hands on the outer or forward face of the wall that is to be presented to view. and to the camera. The method'may be practiced in forming a set that is to present a convex face to the camera, or a concave face. The. fabricating of the wall in each case, necessitates slight variations in the method of securing the abutting edges of the sheets of material together.

In Fig. l I illustrate one end of a platen I, that is preferably of sheet metal form and relatively thin, so that it can be readily bent to any desired curve or arc. In order to enable this thin sheet to support the weight of a wall fabricated upon it, I prefer to provide its under side with a plurality of transverse bars 2 preferably having a cross-section of some structural shape, for example, T-iron. Inusing the platen in fabricating a curved wall 3 such as illustrated in Fig. 1, one end of the platen i would be raised to an elevated position as illustrated in Fig. 1. In order to do this, of course, the platen is left unattached to its support. In other words, as illustrated in the present drawing, the stiffener bars 2 rest unattached on the upper side of side bars 4 of a frame that supports the platen. The end of the platen I may be' connected by a hinge joint 5 to a plate 6 that is carried on the upper side of a transverse head bar I, which may be of channel form, and this bar may be secured to a pair of stanchions 8' that are adjustably secured to blocks 8 at the head of the frame. Any suitable adjusting means may be provided in the present instance, which consists of a bolt l0 secured in the block 9 and passing through a longitudinal slot II. in the stanchion. The

bring the attached faces close together. Due to the inert and inelastic nature of this material, Insulite, the sheets and the longitudinal strips ll readily assume the curve of the upper face of the platen, and it is unnecessary to employ any high degree of pressure to insure an efficient se-- curing of these parts together. v If the fabricated wall is to present its concave face to the camera, then the longitudinal and cross strips are applied on the under side of the layers of wall sheets 23, as indicated in Fig. 2, in which view 24 indicates a cross strip and 25 indicates a longitudinal strip placed over the longitudinal seam, or seams, in the wall sheets 23.

If it is desired to forma cap stringer 21 for the upper edge of the wall, these stringers could be formed on the platen in the same way as the body of the wall, and then attached by cementing the faces of the stringers to the face of the wall body; or, if desired, the

- stringers can be formed directly on the upper stanchion shoud be slotted for a considerable length, and would be attached at its upper end by removable bolts I! to the cross head I. When the platen is not being used to form a curved wall, it would lie flat on the frame, and the stanchions 8 would not be employed. Inorder to provide a positive support for the under side of the platen at the curve, and also in'order to enable it to be given any special form, I provide a plurality of adjustable members l3. These members have their ends attached to the side bars 4, or to the stanchions 8, and-include tumbuckles l4 for adjusting their length. The upper ends of these members are attached to the more or less vertical webs of the stiflener bars 2.

In Fig. 1,'I illustrate the fabrication of awall .in which the convex face of the finished fabricated wall is intended to face the camera. This view illustrates the body of the wall as composed of two layers I5 and iii of Insulite. In forming a wall of this character, the abutting transverse edges ll of the upper layer are covered by transverse strips it, which may be applied intercostal with longitudinal strips I! that are laid over the longitudinal seams or longitudinal abutting edgeslayers 2| and 22. These strips are simply laid in place over the seams after applying the cement or adhesive. and pressed down lightly so as to face of the sheet material by attaching the layers 28 successively, at the same time placing the adhesive between all the layers of material.

It may be necessary to provide means for raising the platen l andholding the same at some intermediate point at an elevated position. In order to enable this to be accomplished, the side bars 4 of the frame of the apparatus may be provided with a series of holes 28 into which the lower ends of suitable adjusting members like the adjusting members ll, may be secured.

After the curved wall section such as illustrated in Fig. 3 is completed, it may be removed from the platen and set up in an upright position. and be secured by adhesive to vertical frame members 34 spaced apart and braced by means of diagonal-braces 3|. These braces can be secured to the vertical members 30 by nails, or by employing small metal fasteners that are driven sidewise across the joint. 4

After the fabricated wall is taken off of th platen, I cover the face that is to be exposed to the camera, with a flexible waterproof fabric 32,

known under the trade name as Fabrikoid.".

Thismaterial can be applied from rolls, and is obtainable in various colors, and with different embossed designs, if desired.

In Fig. 4 I illustrate a portion of a curved fabricated wall 33 formed on the platen in the manner indicated in Fig. 2, so as to leave an unobstructed concave face 34 to which the Fabrikoid 35 is applied. This Fabrikoid is, of course, applied by means of an adhesive.

In this instance, the handling frame for the wall, is located on the convex side of the curve, and may comprise a plurality of vertical frame bars 38 with feet 31 to rest on the floor, and connected by diagonal braces 38.

If it is necessary to .form a set wall with a corner 38 as illustrated in Fig. 6, I prefer to employ a transverse header plate 40, which is set up across the platen and supported on end bars 4|, the lower ends of which are attached bybolts 42 to the side bars 4 of the frame.

Although I have illustrated the plate I vas mounted and operated 'in such a way that it presents a concave upper face to receive the layers of material in practicing my method, it is obvious that if desired, the plate I could be supported adiustably so as to present a convex upper face on which the layers of material could rest in using the method. In any case, the layers base stringer 2! for the bottom of the set, and an upper stringer or.

l forcibly against the lower layers.

of material assume their curved form by the action of gravity. It is unnecessary to clamp them in position or against each other. Howgitudinal tie-strips under the abutting longitudinal edges of the said rows, laying an upper layer of similarsheets lying freely on the flrst' layer ever, it is also obvious that if desired, pressure could be applied to press the uppermost layers This can be more conveniently done on a concave form than on a"-convex form; and, furthermore, I prefer the concave form because it leaves the end edges of the layers at an elevated point, which feature I facilitates the application of the adhesive sub- "mediate legs 43, in adr .tion to the end legs 44, and all of the legs may be braced in place by suitable diagonal braces 45.

. What I claim is:

- 1. A method of forming a rigid fabricated wall of curved shape, which consists in supporting a layer of flexible sheetmaterial disposed in a curve with its concave side uppermost, applying an adhesive and a second layer of flexible material to lie freely upon the upper face of the flrstnamed layer, and thereby permitting the said second layer to assume by the action of gravity, the curved form of the first-named layer to form a curved body, and covering the forward face of the fabricated body with a flexible adhering, sheet presenting a finished surface on its outer side.

2. A'me'thod of forming a rigid fabricated wall of curved shape, the convex face of which is to be presented to view, which consists in supporting a layer of sheets of flexible material with their ends abutting, and with their concave side uppermost, applying an adhesive and a second layer of said'sheets to lie freely upon the upper face of said first layer, so that the said second layer under the action of gravity, assumes the curved form of the first-named layer, and with the ends of the sheets of the second layer abutting each other and forming butt Joints outof line with the abutting ends of the first-named .sheets,

with adhesive connecting the same, and-so that the upper layer assumes by gravity, the curved form ofthe lower sheets, and covering the concave face of the body so fabricated, with an adhering flexible sheet having a finished outer surface.

4. A method of forming a rigid fabricated wall of curved shape, which consists in supporting a layer of flexible sheet material disposed in a ,curve with its concave side uppermost, applying an adhesive, and a second layer of flexible material to lie freely upon the upper face of the first-named layer, and permitting the same to assume by gravity the curved form of the lower sheet to form a curved body, and stiffening the said curved body at separated points by laying and cementing successive layers of strips of similar material on the upper face of the curved body.

5. A method of forming a curved stringer for the upper or lower edge of a curved wall for a moving picture set, which consists in supporting a layer of flexible strip material disposed in a curve with its upper face concave, and applying adhesiveand successive layers of similar material so as to lie freely .on the concave upper face of the same to form a curved rigid fabricated body. f

6. A method of forming alrigid fabricated wall of curved shape, which consists in supporting a layer of flexible sheet material disposed in a curve, applying an adhesive, and a second layer of. flexible material to the upper face of the first,- named layer to lie freely upon the first-named layer so that the same assumes by gravity, the

. curved shape of the first-named layer.

and covering the convex'face of the fabricated porting a layer or rows ofsheets composed of abutting sheets of flexible material disposed in a curve with their concave faces uppermost, placing transverse cross-tie strips under the abutting ends of said sheetswith' adhesive between the faces of the sheets and the tie-strips, laying ion- 7. A method of forming a rigid fabricated wall of curved shape, which consists'in supporting a layer of sheets of flexible material with their ends abutting, and with their concave side uppermost, applying an adhesive and a second layer of said sheets to lie freely upon the upper face of said flrst'layer, so that the said second layer under the action of gravity assumes the curved form of the first-named layer, and with the ends of the sheets of the second layer abutting each other and forming butt joints out of line with.

the abutting ends of the first-named sheets, placing transverse cross tie-strips adjacent the abutting ends of said sheets only on one side of the same with an adhesive between the facesof the-sheets and the tie-strips, and covering the other face of the fabricated body with a flexible adhering sheet havng a finished face on its outer side.

. WALKER E. RUMSEY.

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