Patent Application
20080209850
The present invention relates generally to a device for holding and positioning construction materials. More particularly, the present invention relates to an apparatus and method for holding and positioning construction materials, such as drywall.
Drywall (also commonly referred to as or wallboard or sheetrock) is commonly installed on studs to form the basis for finished interior walls of residential and commercial buildings. While drywall is produced in many sizes, the typical sizes for installation are in sheets four feet wide and eight or twelve feet in length.
Standard pieces or sheets of drywall are heavy and difficult to install by one person alone. Accordingly, at least two people are commonly needed to hold and install these drywall sheets. In construction, time is of the essence as it relates to profitability. Use of multiple people reduces efficiency and, therefore, adds to the cost of construction.
A particular problem associated with drywall or wallboard installation relates to hanging the drywall on upper portions of a stud wall. It is particularly difficult to hold drywall at elevated positions on the stud wall for installation. It is also difficult to hold the drywall so that it remains properly aligned with the stud wall, the ceiling, etc. before being secured in place.
A variety of installation devices exhibiting different levels of complexity are known in the art. For example, the following patents and patent applications describe lifters that generally resemble the letter “T”, with the drywall or other construction material placed at the top and hoisted into position either through a cranking mechanism, screwing device, spring or telescopic means that are arranged on the vertical portion of the device: U.S. Pat. No. 3,930,645 (Anderson); U.S. Pat. No. 4,120,484 (Zimmer); U.S. Pat. No. 4,695,028 (Hunter); U.S. Pat. No. 4,733,844 (Molloy); U.S. Pat. No. 4,928,916 (Molloy); U.S. Pat. No. 5,129,774 (Balseiro et al); U.S. Pat. No. 5,979,854 (Lundgren et al); U.S. Pat. No. 6,082,945 (Jeffries et al); U.S. Pat. No. 6,508,448 (Stewart); U.S. Pat. No. 6,663,084 (Butler); International Patent Application No. PCT/AU95/00382 (WO 96/01353); and UK Patent Application GB 2,260,559. These devices, while useful for their intended purpose, can be bulky and in many cases do not lend themselves to use by a single person.
The following patents describe lifting or positioning devices that rely on the use of a foot to hoist construction materials a few inches from ground level: U.S. Pat. No. 2,692,753 (Masterson); U.S. Pat. No. 2,989,286 (Gillespie); U.S. Pat. No. 3,268,209 (Humbyrd); U.S. Pat. No. 4,712,771 (Donnelly et al); U.S. Pat. No. 5,501,561 (Wulff); U.S. Pat. No. 5,814,842 (Muldoon et al); and U.S. Pat. No. 6,497,399 (Nelson). While suitable for certain types of construction projects, these devices do not permit materials to be positioned at the higher reaches of a wall.
Some of the more complicated devices for lifting drywall and other construction materials are represented by the following patents: U.S. Pat. No. 3,828,942 (Young); U.S. Pat. No. 4,339,219 (Lay); U.S. Pat. No. 4,375,934 (Elliott); U.S. Pat. No. 4,600,348 (Pettit); U.S. Pat. No. 5,640,826 (Hurilla); U.S. Pat. No. 6,010,299 (Jesswein); U.S. Pat. No. 6,176,063 (Warin); U.S. Pat. No. 6,244,810 (Reyes); and U.S. Pat. No. 6,527,492 (Kerns, III et al). In many cases, these devices require assembly before use. In addition, these devices can be bulky and heavy, including such features as tripods and scaffolding. They are consequently better suited for use in commercial construction projects than for home renovation projects, for example.
An example of a more current lifting device is described in United States Patent Application Publication Number US 2001/0029715 A1 (Bradley et al). This publication describes a drywall installation apparatus that includes a support for holding the drywall to be installed, an extension to adjust the length of the drywall installation apparatus, and a base to which a lifting mechanism may be coupled to raise the drywall installation apparatus holding the drywall into a desired position for installation on a stud wall. The drywall installation apparatus includes an alignment member to assist in orienting the piece of drywall to be installed on the stud wall. This alignment member (or “stud guide”) is U-shaped and serves to maintain the drywall installation apparatus in a desired position when a sheet of drywall is being raised or lowered relative to a stud wall. This installation apparatus, while suitable for certain types of walls, such as the stud walls having metal brackets that are favored in many parts of North America, is less convenient for use on other types of wall surfaces.
There is a need, therefore, for a device for holding and positioning construction materials that is simple to use and lightweight, yet sturdy enough to support the weight charge of most construction materials. There is a further need to provide an installation device and method that will allow a single person to hold and install a construction material on a wall, such as drywall, particularly at upper reaches of the wall.
It is, therefore, desirable to provide an improved method and apparatus for lifting or hoisting a variety of construction materials.
It is an object of the present invention to obviate or mitigate at least one disadvantage of previous apparatus and method for lifting or hoisting a variety of construction materials.
The present invention relates to an adjustable support device for holding drywall or gypsum wallboard in place as it is being installed in an elevated position. In one embodiment the elevated position is such that the top edge of the construction materials is at ceiling level, e.g. abuts the ceiling. The device includes an extension section comprising an elongate tubular member and a shaft member telescopically disposed in the elongate tubular member. The extension section is coupled at one end to a support which can receive and hold a piece of drywall during installation. The extension section is further coupled to a base portion at the end opposite to the support. The base includes a pivot feature that serves to lift the drywall once it has been positioned on the support. The extension is adjustable to install drywall on a stud wall at various heights.
Advantageously, this device is lightweight, easy to transport and does not require assembly once on site. It may thus be used immediately upon reaching a construction site, saving on construction time and therefore money. The simplicity of the design should appeal not only to experts in the construction field, but also to novices who engage in home renovation and repair, for example.
Moreover, the device is secure and allows a sheet of drywall to be readily installed by a single person.
The device has the following characteristics:
It can stand alone without support;
It is balanced towards the front (stud wall) in order to permit a vertical lift along a stud wall;
It is suitable for lifting or hoisting a variety of construction materials, including gypsum, drywall, rigid insulation panels, decorative wall panels, plywood, oriented strand board (OSB), chip board, etc. as well as any other flat material that is to be positioned onto a wall;
It may support loads of approximately 500 lbs or more;
It hoists or lifts construction materials through the use of single, light foot pressure performed in a reduced effort manner by the end user;
It adjusts easily to the desired height; and allows the user to lock the construction materials in the elevated position so the user can attach the construction materials using fasteners such as screws, nails, etc.
The device may be made of iron, steel, aluminum or any other metal or metal alloy or non-metallic material such as fiberglass, fiber reinforced plastic, etc. that has the capacity to support the weight of construction materials. Portions of the device may be made of plastic, rubber or other non-metallic material.
In a first aspect, the present invention provides a device for holding and positioning construction materials, having a support for supporting the construction materials, an extension section comprising an elongate tubular member and a shaft member relatively axially adjustable, and a base portion comprising a pivot feature adapted to lift or hoist the construction material into an elevated position once it has been placed on the support, the pivot feature movable between a transport position and an operating position.
In a further aspect, the present invention provides a device for holding and positioning construction materials, having a support for supporting the construction materials, an extension section comprising an elongate tubular member and a shaft member relatively axially adjustable, a base portion comprising a pivot feature adapted to lift or hoist the construction material into an elevated position once it has been placed on the support, and a stand member adapted to support the device, holding the construction material in the elevated position.
In one embodiment the stand member is extendable from the tubular member. In one embodiment, the device includes a locking mechanism for fixing the relative axial position between the stand member and the tubular member. In one embodiment, the shaft member and the tubular member are telescopically disposed. In one embodiment, the shaft member is telescopically disposed in the tubular member. In one embodiment, the tubular member is telescopically disposed in the shaft member. In one embodiment, the device includes a locking mechanism for fixing the relative axial position between the tubular member and the shaft member.
In one embodiment, the base portion is movable between a transport position and an operating position. In one embodiment, the device includes locking means for locking the base portion in the transport position or the operating position. In one embodiment, the device includes a second spring adapted to bias the base portion into the operating position
In one embodiment, the device includes a stabilizer adapted to support the device in a freestanding position. In one embodiment, the stabilizer includes a support plaque oriented at an approximate right angle relative to the pivot feature, the support plaque being substantially planar and extending on either side of the pivot feature. In one embodiment, the stabilizer includes the pivot feature. In one embodiment, the stabilizer includes a first spring.
In one embodiment, the support includes a horizontally projecting support bearing flange. In one embodiment, the support includes a vertically projecting pusher flange.
In one embodiment, the pivot feature includes an elevation element disposed at a position that is approximately within a middle ⅓ portion of the pivot feature. In one embodiment, the elevation element disposed at a distance that is approximately ⅓ the distance from the extension section and approximately ⅔ the distance from the proximal end of the pivot feature.
In one embodiment, the extension section adapted to position the support at an elevated position between about 42″ (1050 mm) and about 60″ (1525 mm).
In one embodiment, the device includes a second spring adapted to bias the base portion into the operating position.
In a further aspect, the present invention provides a device for holding and positioning construction materials including a support for supporting the construction materials, an extension section comprising an elongate tubular member and a shaft member telescopically disposed within said tubular member, a locking mechanism for fixing the relative axial position between the tubular member and the shaft member, a base portion comprising a pivot feature adapted to lift or hoist the construction material into an elevated position once it has been placed on the support for positioning against a wall, the base portion movable between a transport position and an operating position, the base portion comprising a support plaque oriented at an approximate right angle relative to the pivot feature, the support plaque being substantially planar and extending on either side of the pivot feature, a stand member adapted to support the device, holding the construction material in the elevated position, and locking means for locking the base portion in the transport position or the operating position.
In a further aspect, the present invention provides a method for holding and positioning a construction material including providing a device for holding and positioning construction materials, having a support for supporting the construction materials, an extension section comprising an elongate tubular member and a shaft member relatively axially adjustable, and a base portion comprising a pivot feature adapted to lift or hoist the construction material into an elevated position once it has been placed on the support, the pivot feature movable between a transport position and an operating position, supporting the construction material on the device, and lifting or hoisting the construction material into an elevated position using the pivot feature.
In one embodiment, the method includes moving the base portion between a transport position and an operating position.
In one embodiment, the method further includes providing a stand member associated with the device and using the stand member to hold the construction material in the elevated position.
In one embodiment, the construction material is drywall.
Other aspects and features of the present invention will become apparent to those ordinarily skilled in the art upon review of the following description of specific embodiments of the invention in conjunction with the accompanying figures.
Embodiments of the present invention will now be described, by way of example only, with reference to the attached Figures, wherein:
Generally, the present invention provides a method and apparatus for lifting or hoisting a variety of construction materials.
Referring to
Referring to
The extension section 12 includes an elongate tubular member 14 and a shaft member 16 telescopically disposed in the elongate tubular member 14. The shaft member 16 is capable of ready movement within the tubular member 14, so that the device may be manually adjusted to the desired height. As illustrated here, the shaft member 16 includes a locking mechanism 20 that allows the extension section 12 of the device to be secured at a variety of different heights. In one embodiment, the locking mechanism 20 (see
In one embodiment, the extension section 12 is configured to form an angle 250 relative to the wall (
A grip 110 may be provided on the tubular member 14. A tool holder 120 may be provided to support a driver, such as a drill or other power driver.
While shown with the shaft member 16 received within the tubular member 14, one skilled in the art will recognize that there are a variety of configurations that provide relative axial movement between the shaft member 16 and the tubular member 14. For example, the tubular member 14 received within the shaft member 16 is generally concentric, and the tubular member 14 and the shaft member 16 are arranged generally coaxially with a guide or guides extending between the shaft member 16 and the tubular member 14, etc.
The base portion 50 includes a pivot feature 55 that serves to lift the drywall 100 once it has been placed on the support 30 for positioning against a wall. The design of the base portion 50, while simple, allows for the simultaneous support of the drywall when placed on the device 10 and for an end user to lift the drywall through the use of one foot placed on the pivot feature 55. As may be appreciated from the illustration, the base portion 50 includes a support plate or plaque 74 oriented at an approximate right angle relative to the pivot feature. This support plaque 74 extends a distance on either side of the pivot feature 55 to provide improved stability, substantially perpendicular to the tubular member 14.
An elevation element 70 is provided underneath the pivot feature 55. Generally, the pivot feature 55 operates as a lever with the elevation element 70 operating as a fulcrum. In one embodiment, the pivot feature 55 extends from a extension section 12 to a proximal end 57 (i.e., proximal relative to where an end-user would operate the pivot feature 55), with the elevation element 70 disposed in the middle ⅓ portion of that length of the pivot feature 55. In another embodiment, the elevation element 70 is disposed at a distance that is approximately ⅓ the distance from the extension section 12 and approximately ⅔ the distance from the proximal end 57 of the pivot feature 55. In another embodiment, the elevation element 70 is disposed at a distance that is approximately ⅔ the distance from the extension section 12 and approximately ⅓ the distance from the proximal end 57 of the pivot feature 55. In another embodiment, the elevation element 70 is disposed at a distance that is approximately ½ the distance from the extension section 12 and approximately ½ the distance from the proximal end 57 of the pivot feature 55.
As one skilled in the art will recognize, the pivot member provides a levered mechanical advantage, and as the location of the elevation element 70 is nearer the extension section 12, the effort required to lift the drywall 100 will be reduced, but so will the amount of lift available from the pivot feature 55.
The elevation element 70 is shown as a protuberance from the elongate side members 58 but may assume a variety of different configurations. Its purpose is to keep the pivot feature 55 at a slight elevation until the end user is ready to place his or her foot on the pivot feature 55 to lift the drywall to the desired height and position. The pivot feature 55 includes two elongate side members 58 disposed at an approximately right angle relative to an upper member 56 suitable to support the end user's foot when the device is in use. In one embodiment the elongate members 58 have a basic rectangular geometry, but in another embodiment are tapered as they reach the proximal end 57 of the pivot feature 55 and the extension section 12. A spring 65 or other retention means may be included on the device 10 between the pivot feature 55 and the elongate tubular member 14 of the extension section 12, in order to prevent the extension section 12 from rocking about or falling away from the proximal end 57 of the pivot feature 55.
Referring to
In one embodiment, the pivot feature 55 is movable between a transport position and an operating position. In this embodiment, the support plate or plaque 74 may be fixed in place to the extension section, for example with the tubular member 14. In another embodiment, the base portion 50 is moveable between a transport position and an operating position (
A stand member 130 is associated with the device 10 to keep the construction material in the elevated position, even after the user removes his or her foot from the pivot feature 55. The stand member 130 may have an enlarged foot 140. In one embodiment, the stand member 130 is an elongate member slidably retained within a guide 150 along the tubular member 14. A locking means 160 provides for the selective locking/unlocking of the stand member 130 relative to the elongate tubular member 14. In one embodiment, the locking means 160 includes a ring 170 (as shown a square or rectangular ring) connected with the stand member 130. The ring 170 is adapted to slidingly engage the tubular member 14 and having a threaded fastener 162 which is operated by a lever 166 to engage a threaded connection 164, the threaded fastener 162 movable between an engaged position (frictionally engaging the tubular member 14) and a disengaged position (allowing the free movement of the ring 170 and the stand member 130 relative to the tubular member 14). In one embodiment, the stand member 130 is angled such that it causes the device 10 to lean into the wall, forming an angle 250 relative to the floor or grade.
Referring to
Upon pressure by the user upon the pivot feature 55, the base portion 50 and the tubular member 14 now pivot about pin 192 in the stop 230. A channel 210 allows the pin 190 lateral movement to enable the extension section 12 to maintain an inclined vertical stance while providing a substantially vertical lift. The first spring 55 biases the extension section 12 in an upright position within the channel 210.
The geometry and spring rates may be selected such that the first spring 65 and second spring 67 provide approximately balanced forces when the base portion is in the operating position. In one embodiment, the first spring has a spring rate of about 45 lb/in and the second spring has a spring rate of about 6 lb/in.
In operation, the user first adjusts the extension section 12 of the device to an approximate desired height by releasing the locking mechanism 20 and manually extending the shaft member 16 within the tubular member 14. In one embodiment, the height of the support 30 may be adjusted to an elevated position having a height between about 42″ (1050 mm) to about 60″ (1525 mm).
The extension section 12 is then secured by the locking mechanism 20. Next, the user places the construction material on the support 30 of the device 10 and then positions the device 10 with the construction material, for example, drywall 100, close to where the construction material is to be installed. Alternatively, the user may position the device 10 close to where the construction material is to be installed, and then place the construction material on the support 30 of the device 10. In one embodiment the device 10 is placed against proximate or up against a wall. The spacer 240 provides a convenient method of positioning the device 10 against a wall.
With the device 10 in position with the construction material on the support 30 (
Optionally, the locking means 160 may be released to allow the stand member 130 to extend by gravity or otherwise to extend between the device 10 and the floor or grade or scaffolding or work platform etc. that the device 10 is resting upon (
Description of the Features of One Particular Preferred Embodiment, Including Approximate Dimensions:
The height of the support in the device can be adjusted from a height of approximately 42″ (1050 mm) to a height of approximately 60″ (1525 mm). As will be appreciated by one skilled in the art, the adjustable extension section 12 may be manufactured so that it can accommodate a variety of convenient heights.
The device may be made of iron, steel, aluminum or any other metal or metal alloy or non-metallic material such as fiberglass, fiber reinforced plastic, etc. that has the capacity to support the weight of construction materials. Portions of the device may be made of plastic, rubber or other non-metallic material. In one embodiment, the horizontally projecting support bearing flange 34 has the following approximate dimensions: 3″×9″×¼″. The vertically projecting pusher flange 32 for pushing against the front face of the construction material has the following dimensions: 1″×9″×⅛″.
The extension section 12 is made of iron or steel components that are capable of supporting the weight of conventional drywall panels or other construction materials. Any metal or metallic alloy may be selected, as long as it is sturdy enough to support the load of construction materials for hoisting or lifting. In one embodiment, the elongate tubular member 14 is approximately 42″ in length and is square tube with an inner dimension of approximately ⅝| square. The shaft member 16 telescopically disposed in the elongate tubular member 14 is approximately 32″ in length and is square bar with an outer dimension of approximately ½″ square.
The base portion 50 includes a support plaque 74 that has the following approximate dimensions: 2″×9″×⅛″. The pivot feature 55 itself includes two elongate side members 58 that are approximately 18″ in length and 2″ in width disposed at an approximately right angle relative to an upper member 56 that is also approximately 18″ in length and approximately 2″ in width. The elongate side members 58 and the upper member 56 are made of iron, steel or other durable material and have a thickness of approximately 3/16″. Together, the elongate side members 58 and the upper member 56, which comprise the lever portion of the pivot feature 55, create an inverted “U” section bar. Underneath the pivot feature 55, the elevation element 70 provides approximately 3″ of lift (from the upper member 56). A portion of the proximal end 57 of the pivot feature 55 may include a anti-slip or other gripping surface. In one embodiment, the gripping surface includes a perforated section, having a multiplicity of holes through the upper member 56.
As used herein, wall includes a stud wall, whether those “studs” are wood, metal, plastic or otherwise, and includes other surface configurations such as gypsum, drywall, rigid insulation panels, decorative wall panels, plywood, oriented strand board (OSB), chip board, etc., for example when the construction material is being placed over an existing wall, such as when insulation panels are placed over external siding or when a new layer of drywall is placed over an existing layer of drywall. As used herein, wall includes walls without opening and with openings (such as door openings, door frames, doors, window openings, widow openings, windows, etc.).
In the preceding description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the embodiments of the invention. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice the invention.
The above-described embodiments of the invention are intended to be examples only. Alterations, modifications and variations can be effected to the particular embodiments by those of skill in the art without departing from the scope of the invention, which is defined solely by the claims appended hereto.
This application is a continuation-in-part of and claims the benefit of priority of U.S. patent application Ser. No. 11/019,919 filed on Dec. 22, 2004, which is incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11019919 | Dec 2004 | US |
| Child | 12044151 | US |
