Curved Wall Runner with Interlocking Staggered Sections
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Solution Overview
Problem
Conventional construction methods for curved structures like walls, archways, and columns require excessive cuts and are labor-intensive, with existing sheet metal runners being unwieldy and difficult to position effectively.
Innovation Solution
A runner system comprising multiple sections with staggered layers, each with concave and convex portions, and central protrusions, allowing for easy assembly and secure positioning on a radius, compatible with conventional framing practices and techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional straight wall construction methods are used for curved structures, then the structural frame can be assembled, but excessive cuts are required in runners and studs and labor requirements significantly increase
Solution Approach 1:
The runner is divided into multiple modular sections that can be assembled together to form curved structures. Each section contains pre-formed staggered layers with concave and convex portions that interlock, eliminating the need for excessive cutting and fitting of individual studs while maintaining structural integrity
Solution Approach 2:
The runner sections are designed with curved geometries including concave portions at first ends and convex portions at second ends, allowing them to be arranged on a radius to form smooth curved walls without requiring multiple angular cuts and fittings of straight components
2Loss of substance
If sheet metal runners are used to reduce labor and waste, then material efficiency improves, but the runners become unwieldy and difficult to position and retain in desired position
Solution Approach 1:
The runner combines wood or composite materials with metal fastening elements, providing both the structural strength needed to maintain position and the ease of handling associated with wood. The composite construction allows conventional framing techniques to be used while maintaining structural integrity
Solution Approach 2:
The convex portions of runner sections are designed to be received within concave portions of adjacent sections, creating self-aligning and self-retaining joints that automatically position and secure the runner in the desired location without requiring additional positioning equipment or complex retention mechanisms
3Strength
If multiple layers are staggered and offset in the runner sections, then structural strength and resistance to flexing improve, but assembly complexity increases
Solution Approach 1:
The runner is constructed with multiple layers divided into sections that can be assembled incrementally. Each section contains staggered layers that interlock through convex and concave portions, distributing structural strength across multiple simple assembly steps rather than requiring complex single-step assembly
Solution Approach 2:
The offset layers are designed with convex portions that automatically align with and fit into concave portions of adjacent sections, creating self-aligning joints that guide proper positioning during assembly. This self-aligning feature reduces assembly complexity by eliminating the need for precise manual positioning or complex alignment procedures
Data Source
AI summary
The current invention provides a runner for constructing curved surfaces. The runner has at least two sections with each section having at least two layers. The layers used to prepare the sections are substantially identical. However, when assembled to form a section one layer is reversed compared to another layer. Alternatively, each section may be integrally formed. Adjacent sections are pivotal with respect to one another until secured on a desired radius. The runner of the current invention is suitable for constructing curved walls, archways and other curved structures.