Patent Application
20120222385
The disclosure relates to building construction, and in particular to tools to assist lifting and supporting construction panels in position for installation.
In building construction in the U.S., it is conventional to install sheets of drywall and other types of construction panels (such as plywood, paneling, other forms of wall sheeting, and so forth) to ceiling and wall joists. However, construction panels can be large and somewhat cumbersome to position for installation. Drywall, for example, is typically composed of a layer of crushed gypsum pressed between two sheets of thick paper. A standard sheet of drywall is usually 4′ by 8′, or 4′ by 12′, in size, and generally weighs between about 50 to 110 pounds, depending on its constituent materials and dimensions. When drywall and other construction panels are installed to walls and ceilings, it is often necessary for one or more workers to hold the panel in place while others nail or screw it to the underlying joists or supports.
Construction panel lifts, which are sometimes referred to as drywall jacks in drywall-specific applications, are not satisfactory for the range of applications in which they are employed. For example, existing lifts generally include a number of articulating components and/or are complex to maneuver and operate, and in general are quite cumbersome. Further, some lifts do not significantly decrease the labor expense of positioning by hand, because many require one person to attend to the lift at all times to maintain the construction panel in a desired position, while another worker fastens the panel to the installation site. Lacking a second worker, the use of conventional construction panel lifts by a solo worker risks injury and/or inaccurate positioning or installation of a panel.
Illustrative embodiments of construction panel positioning tools and construction panel support tools, and construction panel positioning and support systems employing two or more of such tools, are disclosed herein. An illustrative embodiment of a construction panel positioning tool to position and support at least one edge of a construction panel relative to a panel installation site includes a ramp member and a stabilizing member coupled thereto. The ramp member includes a support platform disposed at an upper end thereof and having an upper surface to receive and support at least an edge portion of a construction panel, and a ramp section adjacent the support platform and extending downward at an angle therefrom. The ramp section is configured to slidingly engage and guide an edge of a construction panel placed thereon toward the support platform, with which it shares a common edge. The stabilizing member is configured to be temporarily secured to or otherwise engage a structural component of a building structure, such as a wall or ceiling joist, to support the ramp member in position. In some panel tool embodiments, the stabilizing member includes a vertical brace, such as to engage and/or be secured to one or more wall joists, with the ramp section projecting at an angle away from the wall joist. When installed with the support platform near ceiling joists, such embodiments may be used to position and then temporarily support an edge of a construction panel in position for installation to the ceiling joists. In some panel tool embodiments, the stabilizing member includes a horizontal brace, such as to engage and/or be secured to one or more ceiling joists.
An illustrative embodiment of a construction panel support tool to temporarily support a construction panel relative to a panel installation site includes a suspension frame and an elongate support member coupled thereto. The suspension frame includes elongate top and bottom guide members collectively configured to slidably engage all four sides of a ceiling joist, and the support member cantilevers away from the suspension frame, and includes a top surface that is spaced, with respect to a ceiling joist with which the suspension frame is engaged, to provide temporary support of a construction panel to the ceiling joist.
in use, an illustrative embodiment of a construction panel positioning and support system, which includes one or more construction panel positioning tools and one or more construction panel support tools, may be used, such as by an individual worker, to assist in maneuvering and holding construction panels in position for installation, for example to ceiling joists in order to form a ceiling. For example, one or more panel positioning tools with vertical stabilizing members may first be fastened to wall joists so the support platforms are near the ceiling joists. A construction panel, such as a sheet of drywall, may be placed with a first or forward edge on the ramp section(s) of the positioning tool(s) and slid upward so the forward edge is supported on the support platform(s) thereof. With the forward edge supported, the worker may lift the opposite edge toward the ceiling joists. A panel support tool suspended on a nearby ceiling joist may then be slid therealong so the support member extends below the construction panel, providing vertical support so the worker can then install the construction panel. The positioning tool(s) may then be removed and the support tool moved away from the installed panel. To install a second panel adjacent the first, a worker may then fasten one or more panel positioning tools with horizontal stabilizing members to the ceiling joists to which the first panel is installed, and use the ramp sections of the positioning tools in the same manner to raise and then support the forward edge of the second panel in place, lifting the opposite edge up to the ceiling, and holding the panel in place by sliding a support member of a panel support tool underneath the panel.
The concepts and components listed above are clarified with reference to the accompanying drawings and detailed description below.
A construction panel positioning and support system 50, which includes one or more construction panel positioning tools (indicated generally at 10) and one or more construction panel support tools (indicated generally at 40), and example embodiments of the individual tools thereof, is shown in
In general, the positioning tool(s) 10 are each adapted to engage and/or be supported on a structural component of a building structure, such as by being removably or temporarily secured to a wall or ceiling joist, and/or a construction panel already installed thereto. Once supported in place, the positioning tools may facilitate guiding a first edge (also referred to herein as a forward edge) of a construction panel, by means of an inclined ramp section, and then temporarily supporting the panel edge on a support platform in a desired position, such as adjacent to a joist to which the panel will then be installed. The support tool(s) 40 are also each adapted to be supported on a structural component, such as by being movably suspended from a ceiling joist, and may facilitate supporting a portion of a construction panel, such as a second edge of a construction panel partially supported on one or more positioning tools, by being moved along the joist into a position in which a support member engages the construction panel portion. As such, the tools may be used separately, or collectively as a system.
For ease of explanation, the illustrative embodiments of the tools 10, 40 shown and described herein are adapted for use with sheets of drywall to be temporarily supported in a generally horizontal orientation adjacent ceiling joists, prior to installation thereto. However, it will be clear from the following description that the tools may be adapted for use with other types of construction panels as well as drywall sheets, any of which may be installed in a variety of orientations (such as vertical, such as for installation to wall joists, or in an angled orientation, such as for installation to joists or other structural beams or supports forming curved or angled walls or ceilings), without departing from the scope of the invention. As such, for example, the directional terms used in the description below are relative and are provided for the sake of clarity, and should not be considered in a limiting sense.
Also, the illustrative tool embodiments shown and discussed below are prototype embodiments fashioned from pieces of industrial steel, such as square tubing and angle steel and so forth, which have been rigidly welded together and/or machined to have the particular characteristics explained herein. Moreover, the specific dimensions, scale, and other measurements thereof are customized for use with standard lumber sizes and construction techniques conventionally used in building construction in the U.S. For example, a wall frame is generally constructed from 2×4 beams of lumber and/or steel braces, with a series of vertical beams (studs) extending between horizontal top and bottom beams (plates). Typically, there are two top plates, one on top of the other, with a parallel series of 2×4 or 2×6 beams extending edgewise across the top plates of opposing wall frames to form the ceiling frame. However, the disclosure should be understood to encompass embodiments that may be constructed to suit other structural beam components or configurations, fabricated from other suitable materials and assembled in other manners, and/or configured to include adjustable or otherwise movable linkages between or among various components and parts of the particular tool.
Two illustrative embodiments of a construction panel positioning tool 10 are discussed first with reference to
A first, non-exclusive, illustrative embodiment of a construction panel positioning tool 10 is shown in
In general and somewhat functional terms, each of the positioning tool embodiments includes an elongate ramp member 12 coupled to a stabilizing member 14, which is configured to engage a structural building component to thereby support the ramp member in a predetermined position relative to an installation site on the building structure. Ramp member 12 includes a support platform 16 disposed at its upper end, and a ramp section 18 disposed adjacent the support platform 16 and configured to extend downwardly at an angle therefrom. The ramp section 18 includes a substantially planar upper surface 20 configured to slidably engage and subsequently guide a forward edge of a construction panel placed on the ramp section toward the support platform 16. The upper surface of the ramp section has an upper edge 22 in common with an upper surface 24 of the support platform 16, which is configured to receive and support at least the forward edge of the construction panel.
In more specific terms, as can be seen from
Thus, in the first embodiment 100, the top plate 108 of the crossbar 106 provides the support platform 16 of the positioning tool 10, with the upper surface 122 of the top plate forming the upper surface 18 of the support platform adapted to receive and support the forward edge of a construction panel such as a drywall sheet. The upper surface 120 of the front bar 102 provides the ramp section 18 of the tool, and the stabilizing member 14 is collectively formed from the rear bar 102, the side plate 110, and the brace member 122. More specifically, the rear surface of the side plate 110 is positioned to abut a horizontal wall joist W, for example a top plate, and be temporarily secured thereto, and the brace member 122 engages the vertical wall joist W. As mentioned above, but although not shown in this view, ceiling joists are typically supported on the top plates, so the tool 100 is generally installed in a position such that the upper surface 122 of the top plate 108 is spaced from the ceiling joist sufficiently to accommodate the thickness of a construction panel. In embodiments that include a brace member, the tool is generally centered (or otherwise positioned) relative to a stud (vertical wall joist W) so that the arms of the brace member loosely engage either side of the stud, such as to provide additional restriction of lateral movement of the tool relative to the wall frame.
In prototype embodiments represented by the first illustrative embodiment 100 of positioning tool 10, ¾″ square tubing was used for the front and rear bars, with the rear bar having an overall length in the range of about 10″ to 18″, and the front bar having an overall length in the range of about 18″ to 24″. The downwardly projecting tip of the front bar, in some of the prototype embodiments, was smoothed or radiused on its upper corner (as shown in
In
In the second embodiment 200, the rear bar 204 provides the support platform 16 of the positioning tool 10, with the upper surface 210 thereof forming the upper surface 24 of the support platform adapted to receive and support the forward edge of a construction panel such as a drywall sheet. The front bar 202 provides the ramp member 12, with the upper surface 206 of the front bar 202 providing the ramp section 18 of the tool. The stabilizing member 14 is in the form of the brace 212.
In prototype embodiments represented by the second illustrative embodiment 200 of positioning tool 10, ¾″ square tubing was used for the front and rear bars, with the rear bar having an overall length in the range of about 2″ to 6″, and the front bar having an overall length in the range of about 18″ to 24″. As with embodiment 100, the downwardly projecting tip of the front bar, in some of the prototype embodiments, was smoothed or radiused on the upper corner (as shown in
A non-exclusive, illustrative embodiment of a construction panel support tool 40 is shown in
In general and somewhat functional terms, support tool 40 includes a suspension frame 42 adapted to movably mount the tool on a ceiling joist C, and a support member 44 coupled thereto and disposed to extend away therefrom in a plane parallel to that of the bottom surface of the ceiling joist C to which the suspension frame 42 is mounted.
More specifically, suspension frame 42 of support tool 300 is shown to be formed from elongate top and bottom guide members 302, 304 coupled to each other by means of struts 306. In particular, top guide member 302 forms a channel adapted to provide at least a clearance fit with the top edge of a ceiling joist C, with the channel defined by parallel sidewalls 308 extending downward from a top wall 310. Bottom guide member 304 includes a sidewall 312 and a bottom wall 314 adapted, respectively, to engage one side and the bottom edge of the ceiling joist C. This configuration allows the entire frame 42 to be suspended from a ceiling joist by “hanging” the top guide member over the top edge at a slight angle, then engaging the bottom wall 314 with the bottom edge of the joist. The struts maintain a predetermined spaced relation between the top and bottom guide members. Optionally, the guide members may be adjustably coupled, such as to accommodate ceiling joists of different widths (for example, 2×8 s, 2×6 s, and 2×4 s are all lumber sizes that are commonly used for ceiling joists). In support tool 300, the adjustability is provided by means of openings along struts 306 through which bolts 316, which protrude from sidewall 312, may extend and be fastened by means of nuts 318.
The support member 44 of support tool 300 is shown to be formed from an elongate bar 320 of square steel tubing that cantilevers in a direction parallel to a longitudinal axis of the support frame, in a plane substantially parallel to, and spaced below, the bottom surface of the ceiling joist. In particular, the spacing is sufficient to accommodate the thickness of a construction panel. Bar 320 is coupled to the suspension frame by means of a pair of bolts 322, which protrude downward from bottom wall 314, and which are fastened by nuts 324. Although not required to all embodiments, this coupling is also shown in support tool 300 to be adjustable, such as to allow a user to adjust the clearance between the top surface of the bar 320 and the bottom surface of the ceiling joist C. The clearance may be determined by user preference, thickness of the particular construction panel with which the support tool is being used, and so forth, but is generally a value greater than the thickness, but less than about twice the thickness, of a construction panel.
In prototype embodiments represented by embodiment 300 of support tool 40, a length of 1″ square tubing having an overall length in the range of about 24″ to 30″ was used for the elongate support bar. The top and bottom guide members both had an overall length in the range of about 6″ to 10″, which was suitable to prevent the suspension frame from rocking or tipping on the ceiling joist when the weight of a sheet of drywall is supported by the support bar.
In some prototypes, instead of bolts, one or both struts extend beyond the bottom guide member to either adjustably (by means of additional openings) or non-adjustably (such as by welding) couple with the support bar. In one variant, the support bar is mounted for a limited range of pivotal movement in a vertical plane on one strut, and a biasing means in the form of a tension spring positioned to bias the distal end of the bar upward, for example to urge the end of the bar against a sheet of drywall supported by the support tool.
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Several configurational variations may be made to the illustrative embodiments within the scope of the invention. For example, although the positioning tools 10 are shown to be of rigid construction, other embodiments may employ hinged, adjustable connections, such as a selectively pivotable coupling between the stabilizing member and the ramp member, so that a single unit relay be employed for installation sites that are adjacent to walls as well as those that are not adjacent to walls, for example by moving the stabilizing member between vertical and horizontal orientations. Further, although the range of angles formed between the ramp section and a horizontal plane in the prototype embodiments is about 35 to 45 degrees, an angle anywhere in the range of about 20 to 60 degrees, or beyond, would have utility in certain applications. Moreover, the inclusion of an adjustable-angle coupling may provide a positioning tool capable of providing such a range. Optionally, the positioning tool components forming the ramp member and/or stabilizing member may be of adjustable length, such as by employing a telescoping configuration, so that the positioning tool may be used in a greater number of applications. For example, ceiling heights in many installations may vary quite a bit, and a positioning tool with a ramp member of adjustable length may allow the vertical distance that a construction panel must be lifted in order to place the forward edge onto a ramp section to be kept minimal. Further, some embodiments of the positioning tools may include additional components, such as braces or supporting struts, as might suitable for a heavier-duty application, and/or multiple iterations of a particular component, such as parallel ramp members, multiple stabilizing members, and so forth; whereas others may include fewer components, such as indicated above, in which some embodiments of a positioning tool does not include a support brace. In some positioning tools, the stabilizing member may instead or additionally couple to the ramp section, and/or may be configured to engage one or more structural components of a building structure in a different manner than as shown. Moreover, the support tools 40 may include a suspension frame that remains in place on a ceiling joist, but may instead (or additionally) feature a slidable and/or pivotable support arm that is movable relative to the suspension frame.
Although the present invention has been shown and described with reference to the foregoing operational principles and illustrated examples and embodiments, it will be apparent to those skilled in the art that various changes in form and detail may be made without departing from the spirit and scope of the invention. The present invention is intended to embrace all such alternatives, modifications and variances that fall within the scope of the appended claims.
