TREA

STUD ALIGNMENT TOOLS, AND METHODS OF MAKING AND USING THE SAME

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Information

  • Patent Application
  • 20240084611
  • Publication Number
    20240084611
  • Date Filed
    September 13, 2023
    a year ago
  • Date Published
    March 14, 2024
    9 months ago
Information
Abstract
Stud alignment tools are disclosed. Methods of making and using stud alignment tools are also disclosed.
Description
FIELD OF THE INVENTION

The present invention relates generally to woodworking tools, in particular, stud alignment tools.


BACKGROUND OF THE INVENTION

The present disclosure helps address known problems in the art faced by construction workers when trying to hold vertical studs to their mating top and bottom plates during stud wall construction. Various problems faced by construction workers include, but are not limited to, twisted boards, the cumbersome act of making sure the board is held at a perpendicular 90-degree angle, especially when trying to hammer a nail through the boards.


There is a continued need in the art for tools that assist with board alignment during stud wall construction.


SUMMARY OF THE INVENTION

The present invention is directed to stud alignment tools suitable for use in aligning and connecting abutting wood boards, for example, during framing of a house or building (e.g., stud wall construction). Accordingly, in some embodiments, the stud alignment tool of the present invention comprises a stud alignment tool comprising: a tool body having an overall T-shape, a tool depth DT extending perpendicular to the overall T-shape, a tool upper surface, and a tool lower surface, wherein the tool body further comprises: a first channel extending from a first side edge of the tool body to an opposite side edge of the tool body, the first channel having a first channel depth DFC that extends from the tool lower surface to a point proximate the tool upper surface; and a second channel extending perpendicular to the first channel and extending from an intersection with the first channel, along a handle portion of the tool body, to a tool lower edge, the second channel having a second channel depth DSC that extends from the tool lower surface to a point proximate the tool upper surface.


The present invention is further directed to methods of making stud alignment tools. In some embodiments, the method of making a stud alignment tool of the present invention comprises molding a stud alignment tool so as to form a tool body having an overall T-shape, a tool depth DT extending perpendicular to the overall T-shape, a tool upper surface, and a tool lower surface, wherein the tool body further comprises: a first channel extending from a first side edge of the tool body to an opposite side edge of the tool body, the first channel having a first channel depth DFC that extends from the tool lower surface to a point proximate the tool upper surface; and a second channel extending perpendicular to the first channel and extending from an intersection with the first channel, along a handle portion of the tool body, to a tool lower edge, the second channel having a second channel depth DSC that extends from the tool lower surface to a point proximate the tool upper surface.


The present invention is even further directed to methods of using stud alignment tools. In some embodiments, the method of using a stud alignment tool of the present invention comprises positioning the stud alignment tool over a first board and a second board extending substantially perpendicular to the first board, the stud alignment tool comprising a tool body having an overall T-shape, a tool depth DT extending perpendicular to the overall T-shape, a tool upper surface, and a tool lower surface, wherein the tool body further comprises: a first channel extending from a first side edge of the tool body to an opposite side edge of the tool body, the first channel having a first channel depth DFC that extends from the tool lower surface to a point proximate the tool upper surface; and a second channel extending perpendicular to the first channel and extending from an intersection with the first channel, along a handle portion of the tool body, to a tool lower edge, the second channel having a second channel depth DSC that extends from the tool lower surface to a point proximate the tool upper surface.


These and other features and advantages of the present invention will become apparent after a review of the following detailed description of the disclosed embodiments and the appended claims.





BRIEF DESCRIPTION OF THE FIGURES

The present invention is further described with reference to the appended figures, wherein:



FIG. 1 is a top perspective view of an exemplary stud alignment tool of the present invention;



FIG. 2 is a bottom perspective view of the exemplary stud alignment tool shown in FIG. 1;



FIG. 3 is a front view of the exemplary stud alignment tool shown in FIG. 1;



FIG. 4 is a rear view of the exemplary stud alignment tool shown in FIG. 1;



FIG. 5 is a left-side view of the exemplary stud alignment tool shown in FIG. 1;



FIG. 6 is a right-side view of the exemplary stud alignment tool shown in FIG. 1;



FIG. 7 is a top view of the exemplary stud alignment tool shown in FIG. 1;



FIG. 8 is a bottom view of the exemplary stud alignment tool shown in FIG. 1;



FIG. 9 is a top perspective view of the exemplary stud alignment tool of the present invention being used to align one board with another board;



FIG. 10 is a top view of the exemplary stud alignment tool of the present invention being used to align one board with another board;



FIG. 11 is a side view of the exemplary stud alignment tool of the present invention being used to align one board with another board;



FIG. 12 is a perspective side view of the exemplary stud alignment tool of the present invention being used to align one board with another board during attachment of the one board to the other board;



FIG. 13 is a top view of the exemplary stud alignment tool of the present invention being used to mark eight (8) inch lengths along a board;



FIG. 14 is a top view of the exemplary stud alignment tool of the present invention (i) being centered along a length mark as shown in FIG. 13, and (ii) used to align one board with another board at the length mark;



FIG. 15 is another view of the exemplary stud alignment tool of the present invention with an optional fastener holding insert;



FIG. 16 is a view of the exemplary stud alignment tool shown in FIG. 15 with the optional fastener holding insert connected to the stud alignment tool; and



FIG. 17 is another perspective view of the exemplary stud alignment tool of the present invention showing multi-angle bubble level indicators along an upper surface of the stud alignment tool.





DETAILED DESCRIPTION OF THE INVENTION

The present invention is directed to stud alignment tools, methods of making stud alignment tools, and methods of using stud alignment tools. FIGS. 1-17 provide views of an exemplary stud alignment tool 100, and its use to connect boards 150/160 to one another using exemplary stud alignment tool 100.


As shown in FIGS. 1, 3, 5, and 7, exemplary stud alignment tool 100 comprises: a tool body 10 having an overall T-shape, a tool depth DT extending perpendicular to the overall T-shape, a tool upper surface 11, and a tool lower surface 12. Tool body 10 further comprises: (a) a first channel 20 extending from a first side edge 13 of the tool body 10 to an opposite side edge 14 of the tool body 10, the first channel 20 having a first channel depth DFC that extends from the tool lower surface 12 to a point 15 proximate the tool upper surface 11; and (b) a second channel 30 extending perpendicular to the first channel 20 and extending from an intersection 17 with the first channel 20, along a handle portion 18 of the tool body 10, to a tool lower edge 19, the second channel 30 having a second channel depth DSC that extends from the tool lower surface 12 to a point 16 proximate the tool upper surface 11.


During use, top board 150 and lower board 160 fit into the channels 20/30 of the tool 10, and in an orientation to allow correct alignment of the boards, for example, during building of a typical stick frame construction. A sight window 50 on the top of the tool 100 allows viewing of the two boards 150/160 in contact with one another in a perpendicular orientation, as the top board 150 is being fastened to the lower board 160. See, for example, FIG. 14. An arrow 52 within the sight window 50 can be used to (i) position the top board 150 on a pre-marked line 155 on the top board 150, and aligned with the arrow 52 of the stud alignment tool 100, and (ii) align the lower board 160 relative to the top board 150 using one or more centering lines 156 on the tool 100 (i.e., centering lines that indicate a center horizontally and vertically for a profile side of the board). See again, for example, FIG. 14.


The underside of the tool 100 may further comprise a cavity (not shown) that hides magnets 60, for example, on both sides of the sight window 50. The magnets 60 allow nails and/or screws 120 to be held on top of the tool 100 for convenience. Optional leveling bubble(s) 80 may be along a tool upper surface 11 of the tool body 10 to help with alignment of the boards 150/160 if needed. In some embodiments, there are a total of 5 levels 80 giving 90-degree and 45-degree indications to a user.


In some desired embodiments, the tool 100 has an 8-inch width WT. Typical centers for stud wall construction are on 16-inch centers. Using an 8-inch width allows a user to quickly mark 8-inch segments along the top board 150 for proper installation at 16-inch standard positions. Arrows (not shown) on the top of the tool 100 may be used to indicate the 8-inch increments.


In some embodiments, the tool 100 may further comprise grip spikes 90, which help the boards 150/160 from moving or slipping once in the channels 20/30. See, for example, FIG. 8. In addition, on the front side surface 102 of the tool 100, a U-shaped notch 70 may be present with a groove 71 molded into its pocket. This U-shape notch 70 is where nails and/or screws 120 may be applied to fasten the lower stud/board 160 to the top board 150 running perpendicular to the lower stud/board 160. The U-shape notch 70 can also receive a disposable insert 75 that can be used when using screws 120. See, for example, FIG. 15. These inserts 75 slide into the molded groves 71 in the U-shaped notch 70. The inserts 75 have a molded wave to them, so they stay in the groove 71 without coming out. The inserts 75 have at least one hole 76 and are notched to receive screws 120 and hold them in place during operation/use. The inserts 75 hold the screws 120 in the correct location for proper fastening, which frees the user's hand to hold the tool 100, and a drill (not shown) to secure the boards 150/160 together.


The stud alignment tools and methods of the present invention may comprise a number of components and/or steps. A description of individual components, and steps is provided below.


Additional Embodiments

Stud Alignment Tools

    • 1. A stud alignment tool 100, said tool 100 comprising:
      • a tool body 10 having an overall T-shape, a tool depth DT extending perpendicular to the overall T-shape, a tool upper surface 11, and a tool lower surface 12, said tool body 10 comprising:
        • a first channel 20 extending along a width WT of said tool body 10 from a first side edge 13 of the tool body 10 to an opposite side edge 14 of the tool body 10, said first channel 20 having a first channel depth DFC that extends from said tool lower surface 12 to a point 15 proximate said tool upper surface 11; and
        • a second channel 30 extending perpendicular to said first channel 20 and along a length LT of said tool body 10 extending from an intersection 17 with said first channel 20, along a handle portion 18 of the tool body 10, to a tool lower edge 19, said second channel 30 having a second channel depth DSC that extends from said tool lower surface 12 to a point 16 proximate said tool upper surface 11. See, for example, FIGS. 1, 3, 5, and 7.
    • 2. The stud alignment tool 100 of embodiment 1, wherein said first channel 20 comprises opposite first channel openings 21 at said first side edge 13 and said opposite side edge 14 of the tool body 10, each of said opposite first channel openings 21 having first channel side walls 22, and a first channel upper wall 23.
    • 3. The stud alignment tool 100 of embodiment 2, wherein said first channel 20 further comprises first channel rounded corners 24 connecting said first channel side walls 22 to said first channel upper wall 23.
    • 4. The stud alignment tool 100 of embodiment 2 or 3, wherein said first channel 20 further comprises first channel rounded lower edges 25 extending from each of said first channel side walls 22 to said tool lower surface 12 of said tool body 10.
    • 5. The stud alignment tool 100 of any one of embodiments 1 to 4, wherein said second channel 30 comprises a second channel opening 31 at said tool lower edge 19 of the tool body 10, said second channel opening 31 having second channel side walls 32, and a second channel upper wall 33.
    • 6. The stud alignment tool 100 of embodiment 5, wherein said second channel 30 further comprises second channel rounded corners 34 connecting said second channel side walls 32 to said second channel upper wall 33.
    • 7. The stud alignment tool 100 of embodiment 5 or 6, wherein said second channel 30 further comprises second channel rounded lower edges 35 extending from each of said second channel side walls 32 to said tool lower surface 12 of said tool body 10.
    • 8. The stud alignment tool 100 of any one of embodiments 5 to 7, wherein each of said second channel side walls 32 of said second channel 30 intersects with side wall portions 26 of said first channel 20.
    • 9. The stud alignment tool 100 of embodiment 8, wherein each of said second channel side walls 32 of said second channel 30 curve as the second channel 30 approaches the first channel 20 so as to become the side wall portions 26 of said first channel 20. See, for example, FIG. 8.
    • 10. The stud alignment tool 100 of any one of embodiments 2 to 9, wherein said first channel side walls 22 are spaced from one another by a first channel width WFC ranging from about 0.75 inch (in) to about 4.0 in.
    • 11. The stud alignment tool 100 of embodiment 10, wherein said first channel width WFC ranges from about 1.5 in to about 2.0 in.
    • 12. The stud alignment tool 100 of embodiment 10 or 11, wherein said first channel width WFC is about 1.75 in.
    • 13. The stud alignment tool 100 of any one of embodiments 5 to 12, wherein said second channel side walls 32 are spaced from one another by a second channel width WSC ranging from about 0.75 in to about 4.0 in.
    • 14. The stud alignment tool 100 of embodiment 13, wherein said second channel width WSC ranges from about 1.5 in to about 2.0 in.
    • 15. The stud alignment tool 100 of embodiment 13 or 14, wherein said second channel width WSC is about 1.75 in.
    • 16. The stud alignment tool 100 of any one of embodiments 1 to 15, wherein said first channel depth DFC ranges from about 1.5 in to about 8.0 in.
    • 17. The stud alignment tool 100 of embodiment 16, wherein said first channel depth DFC ranges from about 2.0 in to about 4.0 in.
    • 18. The stud alignment tool 100 of embodiment 16 or 17, wherein said first channel depth DFC is about 2.5 in.
    • 19. The stud alignment tool 100 of any one of embodiments 1 to 18, wherein said second channel depth DSC ranges from about 1.5 in to about 8.0 in.
    • 20. The stud alignment tool 100 of embodiment 19, wherein said second channel depth DSC ranges from about 2.0 in to about 4.0 in.
    • 21. The stud alignment tool 100 of embodiment 19 or 20, wherein said second channel depth DSC is about 2.5 in.
    • 22. The stud alignment tool 100 of any one of embodiments 1 to 21, wherein said tool depth DT ranges from about 2.5 in to about 9.0 in.
    • 23. The stud alignment tool 100 of embodiment 22, wherein said tool depth DT ranges from about 2.0 in to about 4.0 in.
    • 24. The stud alignment tool 100 of embodiment 22 or 23, wherein said tool depth DT is about 3.0 in.
    • 25. The stud alignment tool 100 of any one of embodiments 1 to 24, wherein said width WT of said tool body 10 ranges from about 6.0 in to about 12.0 in, and said length LT of said tool body 10 ranges from about 6.0 in to about 12.0 in.
    • 26. The stud alignment tool 100 of any one of embodiments 1 to 25, wherein said width WT of said tool body 10 ranges from about 7.0 in to about 10.0 in, and said length LT of said tool body 10 ranges from about 7.0 in to about 10.0 in.
    • 27. The stud alignment tool 100 of any one of embodiments 1 to 26, wherein said width WT of said tool body 10 is 8.0 in, and said length LT of said tool body 10 ranges is about 8.25 in.
    • 28. The stud alignment tool 100 of any one of embodiments 1 to 27, wherein said tool body 10 further comprises a tool handle 40 along said tool upper surface 11 within said handle portion 18 of the tool body 10.
    • 29. The stud alignment tool 100 of embodiment 28, wherein said tool handle 40 is centrally located along said tool upper surface 11 within said handle portion 18 of the tool body 10, and extends from proximate said tool lower edge 19 to said intersection 17 between said second channel 30 and said first channel 20.
    • 30. The stud alignment tool 100 of any one of embodiments 1 to 29, wherein said tool body 10 further comprises a sight window 50 extending from said tool upper surface 11 to within said first channel 20 proximate (or at) said intersection 17 between said second channel 30 and said first channel 20.
    • 31. The stud alignment tool 100 of embodiment 30, wherein said sight window 50 has a circular configuration 51 with a mark alignment arrow 52 extending inward from a side edge 53 of the circular configuration 51.
    • 32. The stud alignment tool 100 of embodiment 31, wherein said mark alignment arrow 52 is aligned with said tool handle 40. See, for example, FIG. 7.
    • 33. The stud alignment tool 100 of any one of embodiments 1 to 32, wherein said tool body 10 further comprises one or more magnets 60 positioned on and/or in and/or below (i) said tool upper surface 11, (ii) a tool side surface 101, or (iii) both (i) and (ii). See, for example, FIGS. 9-10. As discussed herein, one or more magnets 60 may be used to secure nails and/or screws onto an outer surface (e.g., tool upper surface 11) of tool 100.
    • 34. The stud alignment tool 100 of embodiment 33, wherein said one or more magnets 60 are positioned proximate said sight window 50.
    • 35. The stud alignment tool 100 of embodiment 33 or 34, wherein said one or more magnets 60 comprises two magnets 60 positioned along opposite sides of said sight window 50. See again, for example, FIGS. 9-10.
    • 36. The stud alignment tool 100 of any one of embodiments 1 to 35, wherein said tool body 10 further comprises a U-shaped notch 70 extending upward from said tool lower surface 12, said U-shaped notch 70 extending from a tool front side surface 102 into said first channel 20. See, for example, FIGS. 11-12.
    • 37. The stud alignment tool 100 of embodiment 36, wherein said U-shaped notch 70 is aligned with said second channel 30, and said second channel opening 31.
    • 38. The stud alignment tool 100 of embodiment 36 or 37, wherein said U-shaped notch 70 comprises a notch groove 71 extending along an outer periphery 72 of the U-shaped notch 70.
    • 39. The stud alignment tool 100 of any one of embodiments 36 to 38, further comprising a disposable insert 75 sized to fit within and be temporarily attached to said U-shaped notch 70.
    • 40. The stud alignment tool 100 of embodiment 39, wherein said disposable insert 75 has a wavy configuration. See, for example, exemplary disposable insert 75 shown in FIG. 15.
    • 41. The stud alignment tool 100 of embodiment 39 or 40, wherein said disposable insert 75 has one or more insert holes 76 therein, each insert hole 76 being sized to receive a nail (or screw) 120 therein. Typically, disposable insert 75 has two insert holes 76 therein. Each insert hole 76 is sized to receive a nail or screw 120 and hold the nail or screw 120 in place during operation/use to free a user's hand to hold a tool such as a drill (not shown) used to secure boards together.
    • 42. The stud alignment tool 100 of any one of embodiments 1 to 41, wherein said tool body 10 further comprises one or more leveling bubbles 80 positioned along said tool upper surface 11. See, for example, FIG. 17.
    • 43. The stud alignment tool 100 of any one of embodiments 1 to 42, wherein said tool body 10 further comprises from 1 to 5 leveling bubbles 80 positioned along said tool upper surface 11.
    • 44. The stud alignment tool 100 of embodiment 42 or 43, wherein each leveling bubble 80 provides a 90-degree or 45-degree indication to a user.
    • 45. The stud alignment tool 100 of any one of embodiments 1 to 44, wherein said tool body 10 further comprises one or more board gripping spikes 90 positioned within first channel 20 and/or second channel 30. Each board gripping spike 90 helps keep the stud alignment tool 100 “grip” or temporarily attach to a board positioned within first channel 20 and/or second channel 30. See, for example, FIG. 8.
    • 46. The stud alignment tool 100 of any one of embodiments 1 to 45, wherein said tool body 10 comprises a molded tool body 10.
    • 47. The stud alignment tool 100 of any one of embodiments 1 to 46, wherein said tool body 10 comprises an injection molded tool body 10.
    • 48. The stud alignment tool 100 of any one of embodiments 1 to 47, wherein said tool body 10 comprises polypropylene. It should be understood that tool body 10 may be formed from other materials such as one or more materials selected from a polymer (other than polypropylene) such a polyolefin, or an acrylonitrile butadiene styrene (ABS) copolymer, a metal, a ceramic, a cellulosic material (e.g., wood), a foam material, or any combination thereof.
    • 49. The stud alignment tool 100 of any one of embodiments 1 to 48, wherein said tool body 10 further comprises supporting gussets 108 extending along said tool depth DT from said tool upper surface 11 to said tool lower surface 12.


Methods of Making Stud Alignment Tools

    • 50. A method of making the stud alignment tool 100 of any one of embodiments 1 to 49, said method comprising: molding a stud alignment tool 100 so as to form a tool body 10 having an overall T-shape, a tool depth DT extending perpendicular to the overall T-shape, a tool upper surface 11, and a tool lower surface 12, wherein the tool body 10 further comprises: a first channel 20 extending along a width WT of the tool body 10 from a first side edge 13 of the tool body 10 to an opposite side edge 14 of the tool body 10, the first channel 20 having a first channel depth DFC that extends from the tool lower surface 12 to a point 15 proximate the tool upper surface 11; and a second channel 30 extending perpendicular to the first channel 20 and along a length LT of the tool body 10 extending from an intersection 17 with the first channel 20, along a handle portion 18 of the tool body 10, to a tool lower edge 19, the second channel 30 having a second channel depth DSC that extends from the tool lower surface 12 to a point 16 proximate the tool upper surface 11. See again, for example, FIGS. 1, 3, 5, and 7.
    • 51. The method of embodiment 50, wherein said molding step comprises an injection molding step.
    • 52. The method of embodiment 50 or 51, wherein said molding step comprises molding polypropylene. As discussed above, tool body 10 could be formed from other materials such as one or more materials selected from a polymer (other than polypropylene) such a polyolefin, or an acrylonitrile butadiene styrene (ABS) copolymer, a metal, a ceramic, a cellulosic material (e.g., wood), a foam material, or any combination thereof.
    • 53. The method of any one of embodiments 50 to 52, wherein said molding step forms supporting gussets 108 along the tool depth DT from the tool upper surface 11 (or proximate the tool upper surface 11) to the tool lower surface 12 (or proximate the tool lower surface 12).
    • 54. The method of any one of embodiments 50 to 53, wherein said molding step forms a tool handle 40 along the tool upper surface 11 within a handle portion 18 of the tool body 10.
    • 55. The method of any one of embodiments 50 to 54, wherein said molding step forms a sight window 50 extending from the tool upper surface 11 to within the first channel 20 proximate (or at) the intersection 17 between the second channel 30 and the first channel 20.
    • 56. The method of embodiment 55, wherein said molding step forms a mark alignment arrow 52 extending inward from a side edge 53 of a circular configuration 51 of the sight window 50.
    • 57. The method of any one of embodiments 50 to 56, further comprising: incorporating one or more magnets 60 onto and/or into and/or below (i) the tool upper surface 11, (ii) a tool side surface 101, or (iii) both (i) and (ii). See again, for example, FIGS. 9-10.
    • 58. The method of any one of embodiments 50 to 57, wherein said molding step forms a U-shaped notch 70 extending upward from the tool lower surface 12, the U-shaped notch 70 extending from a tool front side surface 102 into the first channel 20. See again, for example, FIGS. 11-12.
    • 59. The method of embodiment 58, further comprising: forming a disposable insert 75 sized to fit within and be temporarily attached to the U-shaped notch 70.
    • 60. The method of any one of embodiments 50 to 59, further comprising: incorporating one or more leveling bubbles 80 into or onto the tool upper surface 11.
    • 61. The method of any one of embodiments 50 to 60, wherein said molding step forms one or more board gripping spikes 90 positioned within first channel 20 and/or second channel 30.


Methods of Using Stud Alignment Tools

    • 62. A method of using the stud alignment tool 100 of any one of embodiments 1 to 49, said method comprising: positioning the stud alignment tool 100 over a lower board 160 and a top board 150 extending substantially perpendicular to the lower board 160, the stud alignment tool 100 comprising a tool body 10 having an overall T-shape, a tool depth DT extending perpendicular to the overall T-shape, a tool upper surface 11, and a tool lower surface 12, the tool body 10 comprising: a first channel 20 extending along a width WT of the tool body 10 from a first side edge 13 of the tool body 10 to an opposite side edge 14 of the tool body 10, the first channel 20 having a first channel depth DFC that extends from the tool lower surface 12 to a point 15 proximate the tool upper surface 11; and a second channel 30 extending perpendicular to the first channel 20 and along a length LT of the tool body 10 extending from an intersection 17 with the first channel 20, along a handle portion 18 of the tool body 10, to a tool lower edge 19, the second channel 30 having a second channel depth DSC that extends from the tool lower surface 12 to a point 16 proximate the tool upper surface 11. See, for example, FIGS. 1, 3, 5, 7, and 9-14.
    • 63. The method of embodiment 62, wherein said positioning step further comprises: moving the stud alignment tool 100 along the top board 150 so as to align a mark alignment arrow 52 of the stud alignment tool 100 with a pre-marked line 155 on the top board 150.
    • 64. The method of embodiment 62 or 63, further comprises: inserting a disposable insert 75 within a U-shaped notch 70 of the tool body 10.
    • 65. The method of any one of embodiments 62 to 64, further comprising: using the stud alignment tool 100 to mark one or more pre-marked line 155 on the top board 150.
    • 66. The method of embodiment 65, wherein the one or more pre-marked line 155 on the top board 150 are spaced from one another by 16 inches.
    • 67. The method of any one of embodiments 62 to 66, further comprising: attaching the top board 150 to the lower board 160 via a nail or screw 120.


In addition, it should be understood that although the above-described stud alignment tools and methods are described as “comprising” one or more components or steps, the above-described stud alignment tools and methods may “comprise,” “consists of,” or “consist essentially of” the above-described components or steps of the stud alignment tools and methods. Consequently, where the present invention, or a portion thereof, has been described with an open-ended term such as “comprising,” it should be readily understood that (unless otherwise stated) the description of the present invention, or the portion thereof, should also be interpreted to describe the present invention, or a portion thereof, using the terms “consisting essentially of” or “consisting of” or variations thereof as discussed below.


As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having,” “contains,” “containing,” “characterized by” or any other variation thereof, are intended to encompass a non-exclusive inclusion, subject to any limitation explicitly indicated otherwise, of the recited components. For example, a stud alignment tool and/or method that “comprises” a list of elements (e.g., components or steps) is not necessarily limited to only those elements (or components or steps), but may include other elements (or components or steps) not expressly listed or inherent to the stud alignment tool and/or method.


As used herein, the transitional phrases “consists of” and “consisting of” exclude any element, step, or component not specified. For example, “consists of” or “consisting of” used in a claim would limit the claim to the components, materials or steps specifically recited in the claim except for impurities ordinarily associated therewith (i.e., impurities within a given component). When the phrase “consists of” or “consisting of” appears in a clause of the body of a claim, rather than immediately following the preamble, the phrase “consists of” or “consisting of” limits only the elements (or components or steps) set forth in that clause; other elements (or components) are not excluded from the claim as a whole.


As used herein, the transitional phrases “consists essentially of” and “consisting essentially of” are used to define a stud alignment tool and and/or a method that includes materials, steps, features, components, or elements, in addition to those literally disclosed, provided that these additional materials, steps, features, components, or elements do not materially affect the basic and novel characteristic(s) of the claimed invention. The term “consisting essentially of” occupies a middle ground between “comprising” and “consisting of.”


Further, it should be understood that the herein-described stud alignment tools and/or methods may comprise, consist essentially of, or consist of any of the herein-described components and features, as shown in the figures with or without any feature(s) not shown in the figures. In other words, in some embodiments, the stud alignment tools of the present invention do not have any additional features other than those shown in the figures, and such additional features, not shown in the figures, are specifically excluded from the stud alignment tools and/or methods. In other embodiments, the stud alignment tools of the present invention do have one or more additional features that are not shown in the figures.


The present invention is described above and further illustrated below by way of examples, which are not to be construed in any way as imposing limitations upon the scope of the invention. On the contrary, it is to be clearly understood that resort may be had to various other embodiments, modifications, and equivalents thereof which, after reading the description herein, may suggest themselves to those skilled in the art without departing from the spirit of the present invention and/or the scope of the appended claims.


Example 1
Method of Making a Stud Alignment Tool

A stud alignment tool 100 as shown in FIGS. 1-17 was prepared using an injection molding process. The tool 100 was formed from polypropylene. The molded tool 100 had a rigid construction with supporting gussets 108 on its exterior side surface 101. This allowed the ability to reduce the amount of material required to produce the tool 100 and keep the rigidity of the tool 100. The tool 100 had a handle 40, as shown, to hold during operation. The tool 100 also had first and second channels 20/30, each of which had a 2-inch channel width (i.e., WFC and WSC).


Example 2
Use of a Stud Alignment Tool

The molded stud alignment tool 100 formed in Example 1 was used in the construction of stud framed walls. It should be noted that the tool 100 could be used in any project where a 2×4 or the like is being fastened to a header board in a perpendicular fashion.


The tool 100 was used by (1) sliding a bottom portion (i.e., handle portion 18) of the tool 100 onto a 2×4 (or the like) board 160, so that the 2×4 is within the vertical channel (i.e., second channel 30) of the tool 100, and (2) sliding an upper portion of the tool 100 onto the top mating board 150 so that the top mating board 150 is within the horizontal channel (i.e., first channel 20) of the tool 100.


The tool 100 had two hidden magnets 60 on either side of a sight window 50. The magnets 60 were used to hold screws and nails 120 during use of the tool 100.


In the middle of the tool 100 right above the handle 40 was a circular window 50. When a vertical stud 160 is placed into the bottom channel 30 of the tool 100, this window 50 provides a visual to make sure that the boards 150/160 are up next to each other. Generally, when installing vertical studs 160 the user will mark on the top plate studs 150 where these vertical studs 160 will be applied (usually in wall construction it is 16-inch centers). This is where the arrow 52 in the sight window 50 comes into play. Here the user can align the arrow 52 to the marking 155 and know they are fixing the center of the vertical stud 160 to the mating top board 150.


In reference to markings 155, the tool 100 can be used as well in marking 16-inch centers as previously described. A user would use the outside flats of the tool 100 when placed on the top board 150, to mark every 8 inches, resulting in 16-inch centers. The tool 100 can be slid down the top board 150 quickly, giving an accurate and reliable 16-inch center marking 155.


Also included in some applications/embodiments of this tool 100, there is at least one bubble level 80, which is in line with the handle 40 and above the sight window 50. This is viewable from the front view as well as the top view of the tool 100. This is to aid in any leveling of a board 150/160 if needed, but also handy for making sure the mating assembly is plumb.


If there is a need to mark the center of a board 150/160 vertically or horizontally across it's profile, there is an indicator for this as well on all sides of the tool 100.


As stated above, the U notch 70 has a groove 71 which allows for the insertion of a thin disposable plate/insert 75. As mentioned, this is installed when a screw gun (not shown) is being used. The user would install the insert 75 and then push in the screws 120 to be held in place. Once in, the user can now, with one hand, drill in the screws 120 without having to hold them. This protects injury from slipping the drill (not shown) off the bit and into the hand. It allows for easier application of these screws 120 without the need to hold them.


The two boards 150/160 were fastened to one another in a perpendicular arrangement, the fastening being done at a front edge 102 of the tool 100 where the U-shaped notch 70 is located. Note, the optional U-shaped notch 70 was designed to work with the width of most industry standard nail guns and screw guns.


While the specification has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing, may readily conceive of alterations to, variations of, and equivalents to these embodiments. Accordingly, the scope of the present invention should be assessed as that of the appended claims and any equivalents thereto.

Claims
  • 1. A stud alignment tool, said tool comprising: a tool body having an overall T-shape, a tool depth DT extending perpendicular to the overall T-shape, a tool upper surface, and a tool lower surface, said tool body comprising: a first channel extending along a width WT of said tool body from a first side edge of the tool body to an opposite side edge of the tool body, said first channel having a first channel depth DFC that extends from said tool lower surface to a point proximate said tool upper surface; anda second channel extending perpendicular to said first channel and along a length LT of said tool body extending from an intersection with said first channel, along a handle portion of the tool body, to a tool lower edge, said second channel having a second channel depth DSC that extends from said tool lower surface to a point proximate said tool upper surface.
  • 2. The stud alignment tool of claim 1, wherein said first channel comprises opposite first channel openings at said first side edge and said opposite side edge of the tool body, each of said opposite first channel openings having first channel side walls, and a first channel upper wall.
  • 3. The stud alignment tool of claim 2, wherein (a) said first channel further comprises (i) first channel rounded corners connecting said first channel side walls to said first channel upper wall, and (ii) first channel rounded lower edges extending from each of said first channel side walls to said tool lower surface of said tool body; and (b) said second channel comprises (i) a second channel opening at said tool lower edge of the tool body, said second channel opening having second channel side walls, and a second channel upper wall, (ii) second channel rounded corners connecting said second channel side walls to said second channel upper wall, and (iii) second channel rounded lower edges extending from each of said second channel side walls to said tool lower surface of said tool body.
  • 4. The stud alignment tool of claim 3, wherein said first channel side walls are spaced from one another by a first channel width WFC ranging from about 0.75 inch (in) to about 4.0 in.
  • 5. The stud alignment tool of claim 3, wherein said second channel side walls are spaced from one another by a second channel width WSC ranging from about 0.75 in to about 4.0 in.
  • 6. The stud alignment tool of claim 1, wherein said first channel depth DFC ranges from about 1.5 in to about 8.0 in, said second channel depth DSC ranges from about 1.5 in to about 8.0 in, and said tool depth DT ranges from about 2.5 in to about 9.0 in.
  • 7. The stud alignment tool of claim 6, wherein said width WT of said tool body ranges from about 6.0 in to about 12.0 in, and said length LT of said tool body ranges from about 6.0 in to about 12.0 in.
  • 8. The stud alignment tool of claim 1, wherein said tool body further comprises a tool handle along said tool upper surface within said handle portion of the tool body, wherein said tool handle is centrally located along said tool upper surface within said handle portion of the tool body, and extends from proximate said tool lower edge to said intersection between said second channel and said first channel.
  • 9. The stud alignment tool of claim 1, wherein said tool body further comprises a sight window extending from said tool upper surface to within said first channel proximate (or at) said intersection between said second channel and said first channel.
  • 10. The stud alignment tool of claim 9, wherein said sight window has a circular configuration with a mark alignment arrow extending inward from a side edge of the circular configuration.
  • 11. The stud alignment tool of claim 1, wherein said tool body further comprises one or more magnets positioned on and/or in and/or below (i) said tool upper surface, (ii) a tool side surface, or (iii) both (i) and (ii).
  • 12. The stud alignment tool of claim 1, wherein said tool body further comprises a U-shaped notch extending upward from said tool lower surface, said U-shaped notch extending from a tool front side surface into said first channel, wherein said U-shaped notch is aligned with said second channel, and said second channel opening.
  • 13. The stud alignment tool of claim 1, wherein said tool body further comprises one or more features selected from: (1) one or more leveling bubbles positioned along said tool upper surface, wherein each leveling bubble provides a 90-degree or 45-degree indication to a user, (2) one or more board gripping spikes positioned within first channel and/or second channel, (3) said tool body comprises a molded tool body, (4) said tool body comprises polypropylene, (5) said tool body further comprises supporting gussets extending along said tool depth DT from said tool upper surface to said tool lower surface, and (6) any combination of (1) to (5).
  • 14. A stud alignment tool, said tool comprising: a tool body having an overall T-shape, a tool depth DT extending perpendicular to the overall T-shape, a tool upper surface, and a tool lower surface, said tool body comprising: a first channel extending along a width WT of said tool body from a first side edge of the tool body to an opposite side edge of the tool body, said first channel having a first channel depth DFC that extends from said tool lower surface to a point proximate said tool upper surface; anda second channel extending perpendicular to said first channel and along a length LT of said tool body extending from an intersection with said first channel, along a handle portion of the tool body, to a tool lower edge, said second channel having a second channel depth DSC that extends from said tool lower surface to a point proximate said tool upper surfacewherein said tool body (1) comprises a molded tool body, and (2) further comprises (i) a sight window extending from said tool upper surface to within said first channel proximate or at said intersection between said second channel and said first channel, and (ii) a tool handle along said tool upper surface within a handle portion of the tool body, wherein said tool handle is centrally located along said tool upper surface within said handle portion of the tool body, and extends from proximate said tool lower edge to said intersection between said second channel and said first channel.
  • 15. The stud alignment tool of claim 14, wherein said tool body further comprises a U-shaped notch extending upward from said tool lower surface, said U-shaped notch (i) extending from a tool front side surface into said first channel, and (ii) being aligned with said second channel, and said second channel opening, wherein said stud alignment tool further comprises a disposable insert sized to fit within and be temporarily attached to said U-shaped notch, said disposable insert comprising one or more insert holes therein, each insert hole being sized to receive a nail or screw therein.
  • 16. The stud alignment tool of claim 14, wherein said first channel depth DFC ranges from about 1.5 in to about 8.0 in, said second channel depth DSC ranges from about 1.5 in to about 8.0 in, said tool depth DT ranges from about 2.5 in to about 9.0 in, said width WT ranges from about 6.0 in to about 12.0 in, and said length LT ranges from about 6.0 in to about 12.0 in.
  • 17. A stud alignment tool, said tool comprising: a tool body having an overall T-shape, a tool depth DT extending perpendicular to the overall T-shape, a tool upper surface, and a tool lower surface, said tool body comprising: a first channel extending along a width WT of said tool body from a first side edge of the tool body to an opposite side edge of the tool body, said first channel having a first channel depth DFC that extends from said tool lower surface to a point proximate said tool upper surface; anda second channel extending perpendicular to said first channel and along a length LT of said tool body extending from an intersection with said first channel, along a handle portion of the tool body, to a tool lower edge, said second channel having a second channel depth DSC that extends from said tool lower surface to a point proximate said tool upper surface;wherein said tool body (1) comprises a molded tool body, and (2) further comprises (i) a sight window extending from said tool upper surface to within said first channel proximate or at said intersection between said second channel and said first channel, (ii) a tool handle along said tool upper surface within a handle portion of the tool body, wherein said tool handle is centrally located along said tool upper surface within said handle portion of the tool body, and extends from proximate said tool lower edge to said intersection between said second channel and said first channel, (iii) one or more leveling bubbles positioned along said tool upper surface, and (iv) supporting gussets extending along said tool depth DT from said tool upper surface to said tool lower surface.
  • 18. The stud alignment tool of claim 17, wherein said tool body further comprises a U-shaped notch extending upward from said tool lower surface, said U-shaped notch (i) extending from a tool front side surface into said first channel, and (ii) being aligned with said second channel, and said second channel opening.
  • 19. The stud alignment tool of claim 17, wherein said first channel depth DFC ranges from about 1.5 in to about 8.0 in, said second channel depth DSC ranges from about 1.5 in to about 8.0 in, said tool depth DT ranges from about 2.5 in to about 9.0 in, said width WT ranges from about 6.0 in to about 12.0 in, and said length LT ranges from about 6.0 in to about 12.0 in.
  • 20. A method of using the stud alignment tool of claim 1, said method comprising: positioning the stud alignment tool over a lower board and a top board extending substantially perpendicular to the lower board, the stud alignment tool comprising a tool body having an overall T-shape, a tool depth DT extending perpendicular to the overall T-shape, a tool upper surface, and a tool lower surface, the tool body comprising: a first channel extending along a width WT of the tool body from a first side edge of the tool body to an opposite side edge of the tool body, the first channel having a first channel depth DFC that extends from the tool lower surface to a point proximate the tool upper surface; and a second channel extending perpendicular to the first channel and along a length LT of the tool body extending from an intersection with the first channel, along a handle portion of the tool body, to a tool lower edge, the second channel having a second channel depth DSC that extends from the tool lower surface to a point proximate the tool upper surface,wherein said positioning step further comprises:moving the stud alignment tool along the top board so as to align a mark alignment arrow of the stud alignment tool with a pre-marked line on the top board.
CROSS-REFERENCE TO RELATED APPLICATION

This patent application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 63/406,035 filed on Sep. 13, 2022 entitled “STUD ALIGNMENT TOOLS, AND METHODS OF MAKING AND USING THE SAME,” the subject matter of which is hereby incorporated by reference in its entirety.

Provisional Applications (1)
Number Date Country
63406035 Sep 2022 US