U.S. patent application number 10/829560 was filed with the patent office on 2004-11-11 for drywall joint and system and process for making.
Invention is credited to House, James Robert, House, Michael Paul, House, William Kenneth.
Application Number | 20040221544 10/829560 |
Document ID | / |
Family ID | 33422485 |
Filed Date | 2004-11-11 |
United States Patent
Application |
20040221544 |
Kind Code |
A1 |
House, William Kenneth ; et
al. |
November 11, 2004 |
Drywall joint and system and process for making
Abstract
A method of making a drywall joint includes steps of positioning
a flexible butt block that has leg portions and has a recessed
surface on an interior side of a joint that is to be formed between
a first drywall sheet and a second drywall sheet, securing at least
one of the first and second drywall sheets to the flexible butt
block so that the secured sheet is made to conform in shape to the
recessed surface, thereby forming a secondary recess on an exterior
of the drywall sheet in the area at which the joint is to be made,
and applying joint compound within the secondary recess.
Inventors: |
House, William Kenneth;
(Forest Lake, MN) ; House, James Robert; (Forest
Lake, MN) ; House, Michael Paul; (Forest Lake,
MN) |
Correspondence
Address: |
KNOBLE YOSHIDA & DUNLEAVY, LLC
Eight Penn Center
Suite 1350
1628 John F. Kennedy Blvd.
Philadelphia
PA
19103
US
|
Family ID: |
33422485 |
Appl. No.: |
10/829560 |
Filed: |
April 22, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10829560 |
Apr 22, 2004 |
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10731324 |
Dec 9, 2003 |
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10731324 |
Dec 9, 2003 |
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10144515 |
May 13, 2002 |
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Current U.S.
Class: |
52/741.4 ;
52/459 |
Current CPC
Class: |
E04F 13/04 20130101;
E04B 2002/728 20130101; E04B 2/7457 20130101; E04F 19/022
20130101 |
Class at
Publication: |
052/741.4 ;
052/459 |
International
Class: |
E04B 002/00 |
Claims
What is claimed is:
1. A method of making a drywall joint, comprising steps of: (a)
positioning a flexible butt block that has a recessed surface on an
interior side of a joint that is to be formed between a first
drywall sheet and a second drywall sheet, wherein said flexible
butt block has a leg portion and a lever point; (b) securing at
least one of the first and second drywall sheets to the flexible
butt block so that the secured sheet is made to conform in shape to
the recessed surface, thereby forming a secondary recess on an
exterior of the drywall sheet in the area at which the joint is to
be made; and (c) applying joint compound within the secondary
recess.
2. The method of making a drywall joint according to claim 1,
wherein flexible butt block has first and second leg portions
wherein step (b) is further performed by securing both the first
and second sheets to the recessed surface, whereby the secondary
recess is formed on an exterior of both of the drywall sheets in
the area at which the joint is to be made.
3. The method of making a drywall joint according to claim 2,
wherein step (b) is further performed by securing first portions of
the respective sheets respectively to the first and second leg
portion, and then securing second portions of the sheets, which are
closer to the area at which the joint is to be made than the first
portions, to the flexible butt block, thereby gradually pulling the
sheets against the recessed surface to form the secondary
recess.
4. The method of making a drywall joint according to claim 1,
wherein step (b) is further performed by securing a first portion
of the sheet to be secured to the leg portion, and then securing a
second portion of the sheet to the flexible butt block that is
closer to the area at which the joint is to be made than the first
portion, thereby gradually pulling the sheet against the recessed
surface to form the secondary recess.
5. The method of making a drywall joint according to claim 1,
wherein step (c) is performed so as to complete a joint that is
substantially planar on an exterior surface thereof.
6. The method of making a drywall joint according to claim 1,
wherein said lever point is more flexible than a center portion of
said flexible butt block.
7. The method of making a drywall joint according to claim 1,
wherein said lever point is more flexible than a leg portion of
said flexible butt block.
8. A flexible butt block for forming a drywall joint, comprising: a
first surface for engaging a first sheet of drywall; a second
surface for engaging a second sheet of drywall; a first leg portion
located at a first distal end of said flexible butt block for
engaging a first sheet of drywall; a second leg portion located at
a second distal end of said flexible butt block for engaging a
second sheet of drywall.
9. The flexible butt block according to claim 8, further
comprising; recess defining means for defining a recessed area
between said first and second surfaces, said recess defining means
being constructed and arranged to be drawn into contact with butt
edge areas of the first and second sheets of drywall when fully
secured to said sheets of drywall, whereby the butt edge areas will
be caused to form a concave secondary recess on an exterior surface
of the drywall joint.
10. The flexible butt block according to claim 8, wherein said butt
block is fabricated from a material that may be penetrated by a
drywall screw and that will provide sufficient anchoring for the
drywall screw for the drywall screw to be able to pull a butt edge
area of a sheet of drywall against the recessed area.
11. The flexible butt block according to claim 8, wherein said
flexible butt block is fabricated from a material comprising
fiberglass.
12. The flexible butt block according to claim 8, further
comprising a first lever point located between said first surface
and said first leg portion and a second lever point located between
said second surface and said second leg portion.
13. The flexible butt block according to claim 12, wherein said
first and second leg portions have a rounded edge.
14. The flexible butt block according to claim 12, wherein said
lever point is more flexible than a center portion of said flexible
butt block.
15. The flexible butt block according to claim 12, wherein said
lever point is more flexible than a leg portion of said flexible
butt block.
16. The flexible butt block according to claim 8, wherein said
first and second leg portions have a substantially flat lower
surface.
17. A drywall joint, comprising: a first sheet of drywall having a
first butt edge; a second sheet of drywall having a second butt
edge, said first and second sheets of drywall being positioned so
that said first butt edge is adjacent to said second butt edge at a
butt interface; recess forming means engaging said first and second
sheets for pulling said first and second butt edges towards first
and second leg portions and first and second surfaces located on a
flexible butt block so as to define a secondary recess in exterior
surfaces of the first and second sheets in the area of the butt
interface; and a sealant applied in said secondary recess.
18. A drywall joint according to claim 17, wherein said sealant
comprises a solidified joint compound.
19. A drywall joint according to claim 17, wherein said sealant is
applied so that an outer surface of said sealant is positioned
substantially within a common plane with exterior surfaces of said
first and second sheets of drywall that are not affected by said
recess forming means.
Description
[0001] This is a continuation in part of U.S. patent application
Ser. No. 10/731,324, filed Dec. 9, 2003, which in turn is a
continuation U.S. patent application Ser. No. 10/144,515, filed May
13, 2002, of the entire disclosures of which are hereby
incorporated as if set forth fully herein.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] This invention relates generally to the field of
architecture and construction. More specifically, this invention
relates to the field of drywall construction, which is the most
common method that is used today to finish interior walls and
ceilings in buildings such as new homes and offices.
[0004] 2. Description of the Related Technology
[0005] Conventional drywall is fabricated in sheets having a gypsum
core that is contained within a fibrous, cardboard-like outer skin.
Drywall sheets typically are approximately four feet to in width by
eight feet in height, although this may vary depending upon the
manufacturer and the part of the world in which the product is
being used.
[0006] Conventional frame-type construction involves assembling the
structural portion of a wall or ceiling from a framework that is
constructed of a plurality of joists, which are typically 2.times.4
pieces of lumber. The drywall must be fastened over the framework
of joists to form the outer surface of the wall or ceiling. Since a
number of drywall sheets will usually have to be applied to a
particular wall or ceiling surface to completely cover the
structural framework of the wall or the ceiling, the individual
sheets of drywall will have to be joined together in a way that is
not easily detectable to a viewer after the wall has been
finished.
[0007] FIG. 1 depicts a conventional drywall joint 10 that is the
most typical example of the current state of construction in this
area. As shown in FIG. 1, a first drywall sheet 12 is positioned
end-to-end with a second drywall sheet 14, with adjacent edges of
the two sheets 12, 14 positioned together in a butt-type interface
16. Because of the irregularities that are unavoidable in
joist-type construction, it is considered preferable to have the
butt interfaces 16 between the different sheets of drywall
positioned over an open area within the structural framework, and
not directly over one of the joists. Instead, a support member 18
is positioned behind the two drywall sheets 12, 14 in order to
provide rigidity to the joint and give alignment to the drywall
sheets 12, 14 during the joining process. As FIG. 1 shows, the
drywall sheets are first joined to the support member 18 by a pair
of drywall screws 20, 22. After the drywall screws 20, 22 have been
so secured, a second pair of screws 24, 26, which are closer to the
butt interface 16, are then inserted and secured between the
support member 18 and the respective drywall sheets 12, 14.
[0008] At this point, the first and second drywall sheets 12, 14
are joined together structurally, but are still aesthetically quite
distinguishable. To hide the visible crack of the butt interface
16, a length of adhesive mesh drywall joint tape 28 is applied to
the crack at the butt interface 16, and a substance that is known
as joint compound 30, or more commonly by the term "mud," is
trowled on top of the tape 28 and is spread as smoothly as possible
outwardly over the exterior surface of the two drywall sheets 12,
14 so as to disguise the joint 10 from view as effectively as
possible.
[0009] Unfortunately, the added thickness of the joint tape 28 and
the joint compound 30 creates a bulge 32 at the conventional
drywall joint 10. A skillful contractor will be able to disguise
the bulge 32 as well as it can be disguised, mainly by spreading
the joint compound outwardly for some distance, but there are some
instances in which the bulge 32 will remain noticeable, such as
when there is overhead spot lighting that will strike the bulge 32
obliquely, which will tend to make the bold 32 very evident to even
the least discerning viewers.
[0010] In addition to the disadvantages of the conventional drywall
joint 10 that are discussed above, it takes a great amount of time
and material to smooth the conventional drywall joint 10 when one
considers the number of such joints that will have to be made in
the construction of a large building such as a house.
[0011] A need exists for an improved drywall joint and a system and
process for making such a joint that will reduce the amount of
labor and materials necessary to form the joint, and that will
enhance the aesthetic value of the finished joint.
SUMMARY OF THE INVENTION
[0012] Accordingly, it is an object of the invention to provide an
improved drywall joint and a system and process for making such a
joint that will reduce the amount of labor and materials necessary
to form the joint, and that will enhance the aesthetic value of the
finished joint.
[0013] In order to achieve the above and other objects of the
invention, a method of making a drywall joint according to a first
aspect of the invention includes steps of positioning a flexible
butt block that has a recessed surface on an interior side of a
joint that is to be formed between a first drywall sheet and a
second drywall sheet, wherein the flexible butt block has a leg
portion and a lever point. Securing at least one of the first and
second drywall sheets to the flexible butt block so that the
secured sheet is made to conform in shape to the recessed surface,
thereby forming a secondary recess on an exterior of the drywall
sheet in the area at which the joint is to be made. Applying joint
compound within the secondary recess.
[0014] According to a second aspect of the invention, a flexible
butt block for forming a drywall joint. The flexible butt block has
a first surface for engaging a first sheet of drywall. The flexible
butt block has a second surface for engaging a second sheet of
drywall. The flexible butt block has a first leg portion located at
a first distal end of the flexible butt block for engaging a first
sheet of drywall. The flexible butt block has a second leg portion
located at a second distal end of the flexible butt block for
engaging a second sheet of drywall.
[0015] According to a third aspect of the invention, a drywall
joint having a first sheet of drywall having a first butt edge. The
drywall joint has a second sheet of drywall having a second butt
edge, the first and second sheets of drywall being positioned so
that said first butt edge is adjacent to said second butt edge at a
butt interface. The drywall joint further has recess forming means
engaging the first and second sheets for pulling the first and
second butt edges towards first and second leg portions and first
and second surfaces located on a flexible butt block so as to
define a secondary recess in exterior surfaces of the first and
second sheets in the area of the butt interface and a sealant
applied in the secondary recess.
[0016] These and various other advantages and features of novelty
that characterize the invention are pointed out with particularity
in the claims annexed hereto and forming a part hereof. However,
for a better understanding of the invention, its advantages, and
the objects obtained by its use, reference should be made to the
drawings which form a further part hereof, and to the accompanying
descriptive matter, in which there is illustrated and described a
preferred embodiment of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a fragmentary cross-sectional view depicting a
conventional drywall joint;
[0018] FIG. 2 is a perspective view of a butt block that is
constructed according to a preferred embodiment of the
invention;
[0019] FIG. 3 is a fragmentary cross-sectional view depicting a
first method step in a process that is performed according to a
preferred embodiment of the invention;
[0020] FIG. 4 is a fragmentary cross-sectional view depicting a
second method step in the process that is first shown in FIG. 3;
and
[0021] FIG. 5 is a fragmentary cross-sectional view depicting a
completed joint that is constructed according to a preferred
embodiment of the invention;
[0022] FIG. 6 is a frontal view of the flexible butt block;
[0023] FIG. 7 is a fragmentary cross-sectional view depicting a
first method step in a process that is performed using the flexible
butt block;
[0024] FIG. 8 is a fragmentary cross-sectional view depicting a
second method step of the process shown in FIG. 7 using the
flexible butt block;
[0025] FIG. 9 is fragmentary cross-sectional view depicting a
completed joint that is constructed using the flexible butt
block.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
[0026] Referring now to the drawings, wherein like reference
numerals designate corresponding structure throughout the views,
and referring in particular to FIG. 2, a butt block 40 constructed
according to a preferred embodiment of the invention includes a
first outboard flange 42 and a second outboard flange 44. As may be
seen in FIG. 2, the first outboard flange 42 includes a first
surface 46 defined by a forward portion of the flange 42. The
second flange 44 likewise is provided with a second surface 48 on a
front portion thereof. The purpose of first and second surfaces 46,
48 is to engage the interior surfaces of first and second sheets of
drywall 12, 14, as will be described in greater detail below. The
first and second surfaces 46, 48 are substantially planar, and
preferably lie within substantially the same plane.
[0027] Referring again to FIG. 2, it will be seen that butt block
40 further includes recess defining structure 50 that is embodied
as a first recessed panel 52, and a second recessed panel 54. The
recessed panels 52, 54 are unitary with each other and are joined
at a center axis 56 that is located at the innermost point of the
recess that is defined by the recess defining structure 50. The
first recessed panel 52 is unitary with the first flange 42, while
the second recessed panel 54 is similarly unitary with the second
flange 44. The butt block 40 is fabricated from a material that is
capable of being penetrated by a standard drywall screw, and that
is traditionally capable of entering such screws to the extent
necessary to perform the steps that are described with reference to
FIGS. 3,4 and 5 below. In the preferred embodiment, this material
is fiberglass.
[0028] Referring now to FIG. 3, a method of making an improved
drywall joint according to a preferred embodiment of the invention
will now be described. As FIG. 3 shows, the butt block 40 that has
been described in reference to FIG. 2 is cut to an appropriate
length, and is then positioned behind first and second drywall
sheets 12, 14 that are desired to be joined. This is in most cases
performed so that the butt block 40 will be positioned in a void
that is defined by adjacent joists within a framework for a wall or
a ceiling. The butt block 40 is preferably positioned, as shown in
FIG. 3, so that the center axis 56 is substantially aligned with
the butt interface 16 between the edges of the drywall sheets 12,
14 that are to be joined. This alignment may be accomplished by
temporarily placing a number of drywall screws into the butt block
40 along the center axis 56 and then sliding the butt block 40
behind one of the drywall sheets 12, 14 until these temporarily set
drywall screws abut the edge of the drywall sheets 12, 14.
[0029] As FIG. 3 shows, a first series of drywall screws 60 are
used to secure the first flange 42 of the butt block 40 to a
portion of the first drywall sheet 12 that is located some distance
from the butt interface 16. Immediately thereafter, a second series
of drywall screws 62 are similarly driven into the second drywall
sheet 14 to secure a corresponding portion of the sheet 14 to the
second flange 44 of the butt block 40. These actions cause the
first and second surfaces 46, 48 that are described in reference to
FIG. 2 to be drawn tightly against interior surfaces 68, 70 of the
respective sheets 12, 14.
[0030] At this point in time, the exterior surfaces 64, 66 of the
respective drywall sheets 12, 14 are substantially aligned with
each other in substantially the same plane as the rest of the
drywall sheets 12, 14, much in the manner as is shown in the
conventional joint that is depicted in FIG. 1.
[0031] Referring now to FIG. 4, the preferred embodiment of the
invention further includes steps of driving a third series of
screws 74 into portions of the first drywall sheet to 12 that are
fairly close to the butt interface 16. At about the same time, a
fourth series of screws 76 are driven into portions of the second
drywall sheet 14 that are fairly close to the butt interface 16. As
the screws 74, 76 are tightened, the area of the drywall sheets 12,
14 that are adjacent to the butt interface 16 are drawn into the
recess 72 that is defined by the recess defining structure 50 in
the butt block 40, thereby creating a secondary recess 78 to be
formed on the exterior surface of the joint. In other words, the
exterior surfaces 64, 66 of the drywall sheets 12, 14 become
pitched inwardly toward the butt interface 16, as is clearly shown
in FIG. 4.
[0032] Looking now to FIG. 5, the secondary recess 78 that is shown
in FIG. 4 will now be filled by a process that includes applying an
adhesive mesh joint tape that is of conventional construction over
the butt interface 16, and then applying a joint compound 82 to
fill the rest of the secondary recess 78. This is preferably
performed so that the resulting joint 86 has a planar exterior
surface that lies within the same plane 84 as the main portions of
the first and second sheets 12, 14 of drywall.
[0033] Referring now to FIG. 6, a preferred embodiment of the
invention using flexible butt block 140 is shown. Flexible butt
block 140 provides excellent flexibility so that it has more
versatility when forming a recess and further creates a
well-defined recess that runs the length of the joint.
[0034] In forming the recess, drywall 14 is attached to stud 190
with exterior surfaces 64 and 66 facing out. Flexible butt block
140 is positioned behind drywall 14 facing interior surfaces 68 and
70. Flexible butt block 140 is attached at screw reception areas
172 located on leg portion 159 using first set of drywall screws
139. This insures that drywall butt 182 is in line with central
axis 156 of flexible butt block 140. Drywall 12 is then attached to
stud 192. Drywall butts 181 and 182 form butt interface 16 and are
aligned with central axis 156 of flexible butt block 140. Drywall
12 is then attached to the flexible butt block 140 at screw
reception areas 174 located on leg portion 157 using second set of
drywall screws 138. Leg portions 157 and 159 assist in providing
easy attachment of flexible butt block 140 to drywall 14 and
drywall 12.
[0035] Drywall 14 is then attached to flexible butt block 140 at
approximately {fraction (3/8)} of an inch from drywall butt 182
with drywall screws 137. Drywall 12 is attached to flexible butt
block 140 at approximately {fraction (3/8)} of an inch from drywall
butt 181. Drywall 14 is drawn towards central axis 156 via the
action of third set of drywall screws 137 being attached at screw
reception areas 132, thereby creating a force of approximately 65
PSI (PSI figures are based on {fraction (5/8)} inch of
Sheetrock.TM. (drywall)). Drywall 12 is drawn towards central axis
156 via the action of fourth set of drywall screws 136 being
attached at screw reception areas 130, thereby creating a force of
approximately 65 PSI. A force greater than the PSI created by the
attachment of sets of screws 137 and 136, is created at lever
points 155 and 153, forcing leg portions 159 and 157 to follow the
upward recesses. Lever points 155 and 153 are designed to be more
flexible than central axis 156. At the ends of leg portions 157 and
159, rounded portions 160 and 162 serve to provide clearance during
the attachment of flexible butt block 140 and after attachment of
flexible butt block 140. Rounded portions 160 and 162 also assist
in the lever action.
[0036] Flexible butt block 140 is designed to collapse downwards at
central axis 156 by approximately {fraction (1/32)} of an inch,
although this distance can vary, or until a force greater than the
65 PSI created via the action of sets of drywall screws 137 and 136
being placed within screw reception areas 132 and 130,
respectively, thereby creating a lever effect at lever points 155
and 153. Rounded portions 160 and 162 facilitate the lever effect.
The effect of the lever action helps to secure flexible butt block
140 to drywall 14 and drywall 12 and creates a well-defined recess
formed by exterior surfaces 64 and 66.
[0037] Testing has found that recessed panels 152 and 154 of
flexible butt block 140 formed left and right of central axis 156
operate with the same lever effect but independent of each other.
Total collapse of flexible butt block 140 at central axis 156 could
not be achieved at 200 PSI well over the amount of PSI created via
the action of sets of drywall screws 136, 137, 138, and 139 on
central axis 156 (approximately 130 PSI at central axis 156),
upward lever effect at lever points 155 and 153 was approximately
160 PSI. These pressures will change depending on the gauge of the
drywall used.
[0038] FIG. 7 shows flexible butt block 140 in position before sets
of drywall screws 136, 137, 138, and 139 are attached. Flexible
butt block 140 is placed adjacent drywall 12 and drywall 14.
Central axis 156 of flexible butt block 140 is aligned with butt
interface 16. Sets of drywall screws 136, 137, 138, and 139 are
placed in position to be attached to screw reception areas 130,
132, 172, and 174.
[0039] FIG. 8 shows flexible butt block 140 attached to drywall 12
and drywall 14. Screw sets 138 and 139 are first attached to screw
reception areas 174 and 172 thereby drawing drywall 12 and drywall
14 towards leg portions 157 and 159. At this point the angle
measured from central axis 156 to the surface of flexible butt
block 140 between central axis 156 and lever point 153 is roughly
3.5.degree.. The angle measured from central axis 156 to the
surface of flexible butt block 140 between central axis and lever
point 155 is roughly 3.5.degree.. Also at this point in time the
angle measured from the surface of drywall 12 and drywall 14 to the
bottom of leg portions 157 and 159 is roughly 0.degree..
[0040] Sets of drywall screws 136 and 137 are then attached to
screw reception areas 130 and 132. The attachment of sets of
drywall screws 136 and 137 draw drywall 12 and drywall 14 towards
flexible butt block 140 and additionally causes force to be applied
via the action of lever points 153 and 155 and the flexibility of
leg portions 157 and 159 enhanced by rounded portions 160 and 162.
The force generated by the action of lever points 153 and 155
further presses central axis 156 towards drywall 12 and drywall 14.
After the lever action, the angle measured from central axis 156 to
the surface of flexible butt block 140 between central axis 156 and
lever point 153 is roughly 3.0.degree.. The angle measured from
central axis 156 to the surface of flexible butt block 140 between
central axis and lever point 155 is roughly 3.0.degree.. Also at
this point in time the angle measured from the surface of drywall
12 and drywall 14 to the bottom of leg portions 157 and 159 is
roughly 2.0.degree..
[0041] The lever action helps secure drywall 12 and drywall 14 to
flexible butt block 140, and further assists in creating a well
defined recess formed by exterior surfaces 64 and 66 of drywall 12
and drywall 14. The recess formed by exterior surfaces 64 and 66,
shown in FIGS. 8 and 9, as well as the V gap formed below central
axis 156 shown in FIGS. 8 and 9, are exaggerated in order to
illustrate the invention. The recess formed by exterior surfaces 64
and 66, is {fraction (3/32)} inches deep before the lever action at
lever points 153 and 155 when measured from the interface of
exterior surfaces 64 and 66 to a point substantially parallel with
the remaineder of the main portions of the first and second sheets
12, 14 of drywall, and is {fraction (1/16)} inches or less deep
after the lever action of lever points FIG. 9 shows the final step
in forming the joint. An adhesive mesh joint tape that is of
conventional construction, preferably having a thickness of 0.008
inches and roughly 2 inches wide, is applied over the butt
interface 16, and then a joint compound 82 is used to fill the
recess created by attaching flexible butt block 140. This is
preferably performed so that the resulting joint has a planar
exterior surface that lies within the same planes as the main
portions of the first and second sheets 12, 14 of drywall. When
drywall compound 82 and tape are applied to butt interface 16, the
water in the joint compound 82 weakens first and second sheets 12
and 14 of drywall and first and second sheets 12 and 14 of drywall
will retain their new shape when dry. This further conforms drywall
sheets 12 and 14 to the butt block 140.
[0042] The material most ideal for the construction of flexible
butt block 140 was found to be fiberglass, however other materials,
such as metal or wood can be used. Fiberglass is superior in screw
retention and when it comes to keeping its physical properties with
heat. It will hold its shape at temperatures greater than
170.degree. F. and is not negatively affected by cold. Fiberglass
will try to reform its shape.
[0043] It is to be understood, however, that even though numerous
characteristics and advantages of the present invention have been
set forth in the foregoing description, together with details of
the structure and function of the invention, the disclosure is
illustrative only, and changes may be made in detail, especially in
matters of shape, size and arrangement of parts within the
principles of the invention to the full extent indicated by the
broad general meaning of the terms in which the appended claims are
expressed.
* * * * *