U.S. patent application number 13/088440 was filed with the patent office on 2011-11-10 for wall attachment system comprised of a wood fastener and method involving suspension.
Invention is credited to Charles R. Horn, John E. Nelson.
Application Number | 20110271619 13/088440 |
Document ID | / |
Family ID | 44900981 |
Filed Date | 2011-11-10 |
United States Patent
Application |
20110271619 |
Kind Code |
A1 |
Nelson; John E. ; et
al. |
November 10, 2011 |
WALL ATTACHMENT SYSTEM COMPRISED OF A WOOD FASTENER AND METHOD
INVOLVING SUSPENSION
Abstract
A wood fastener according to principles of the invention
comprises a wood unit having at least one upper and one lower
groove. The grooves are offset. The grooves have sufficient depth
and width to allow a nail or similar fastener to extend
therethrough and also allow passage of a reciprocating saw blade.
The side ends are trimmed to mesh with furring strips. The fastener
includes one or more starter holes to facilitate use by guiding
placement and insertion of screws or nails. In use, the fastener
attaches a movable wall to bracing provided in finished walls and
ceilings of a room. To facilitate removal of the fastener for
rearrangement of the wall, nails or screws extending through the
grooved sections of the fastener may be cut using a reciprocating
saw. A method for using the fastener is also provided.
Inventors: |
Nelson; John E.; (Orange
Park, FL) ; Horn; Charles R.; (Jacksonville Beach,
FL) |
Family ID: |
44900981 |
Appl. No.: |
13/088440 |
Filed: |
April 18, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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61332741 |
May 7, 2010 |
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Current U.S.
Class: |
52/243.1 ;
52/698; 52/745.09; 52/745.21 |
Current CPC
Class: |
E04B 2/7457 20130101;
E04B 2/82 20130101 |
Class at
Publication: |
52/243.1 ;
52/698; 52/745.09; 52/745.21 |
International
Class: |
E04B 2/82 20060101
E04B002/82; E04B 2/74 20060101 E04B002/74; E04B 1/38 20060101
E04B001/38 |
Claims
1. A fastener used for attaching a wall to a structure, said
fastener comprising: a body comprised of a construction material,
said body having a top and a bottom; a top groove formed in the top
of the body, said top groove having a first depth and a first
width; a bottom groove formed in the bottom of the body, said
bottom groove having a second depth and a second width; the top
groove and the bottom groove being unaligned and not overlapping;
and the first width and the second width each being sufficient to
accommodate a nail and a reciprocating saw blade.
2. A method of providing a room with a movable nonbearing wall,
said room having a room height and a room width, a ceiling, a floor
and at least a pair of opposed walls, and said movable wall
comprising a wood framework and gypsum wallboard, said method
comprising steps of: constructing the room with bracing, said
bracing comprising support structures at the ceiling and at each of
the pair of opposed walls, where the movable nonbearing wall may be
attached, finishing the ceiling and walls before the movable
nonbearing wall is attached, said step of finishing concealing the
bracing; providing a plurality of removable fasteners, said
removable fasteners each having a fastener height and width;
providing a movable nonbearing wall having a wall height and a wall
width less than the room height and room width, the difference
between the wall height and room height being about twice the
height of each removable fastener, the difference between the wall
width and the room width being about twice the height of each
removable fastener, attaching the plurality of removable fasteners
to the removable wall and to the bracing, said fasteners being
disposed between the movable wall and the bracing at least at the
ceiling and the pair of opposed walls.
3. A method of providing a room with a movable nonbearing wall
according to claim 2, wherein the room has been constructed with
bracing in at least two locations where the moveable wall may be
attached, and said room is further constructed with an electrical
system, HVAC system, window, door frame and fire safety device
configured to maintain utility of said electrical system, HVAC
system, window, door frame and fire safety device regardless of the
location at which the movable nonbearing wall is attached to the
bracing.
4. A method of providing a room with a movable nonbearing wall
according to claim 2, wherein the moveable wall is temporarily
suspended above the floor by attaching the moveable wall to bracing
along the opposed walls and ceiling, allowing flooring to be
installed beneath the moveable wall.
5. A method of providing a room with a movable nonbearing wall
according to claim 2, further comprising an connecting electrical
receptacle at bracing at one of the pair of opposed walls, a
conduit from said connecting electrical receptacle to an adjacent
source electrical receptacle to which electric power is supplied, a
conduit extending in said moveable wall from a receiving electrical
receptacle to an edge of the wall adjacent to the connecting
electrical receptacle, said conduits allowing electric cable to
electrically couple the source electrical receptacle to the
receiving electrical receptacle via the connecting electrical
receptacle.
6. A wood fastener as described in the detailed description
above.
7. A wood fastener as depicted in the figures.
8. A method of using a wood fastener to install and remove a wall
as described in the detailed description above.
9. A movable wall, removably attached to a support structure via a
wood fastener as described in the detailed description above.
10. A suspended wall having a top edge, a bottom edge and two side
edges, the bottom edge being elevated above a floor, and at least
one of the top edge and the side edges being fastened to a support
structure.
11. A movable wall, removably attached to a support structure via a
wood fastener as shown in the figures.
12. A wood fastener used for attaching a wall to another wall,
ceiling or floor, and which has grooves on opposite sides to enable
screws or nails to be cut or pried so that a fastener can be
removed.
13. The fastener of claim 1 in which notches are routed into four
corners of the fastener where furring strips can be tacked to
support edges of drywall affixed to a movable wall.
14. The fastener of claim 1 in which at least one long edge is
routed to act as a guide to move a wall into place on a wood
fastener.
15. The fastener of claim 1 in which two predrilled voids serve as
guides for a nail or screw in a first and second use as the nail or
screw passes through drywall and an underlying stud and in which
the voids guide the nail or screw at such an angle where both the
wood fastener cannot rotate on gypsum finish and where the nails or
screws will be completely embedded in wood on the opposite side of
gypsum.
16. The fastener of claim 1 in which a wood fastener is painted a
bright color on its edges so that they will be noticed when
demolition begins.
17. The fastener of claim 1 in which a "center" line is marked on
the fastener.
18. The fastener of claim 1 in which the fastener has instructional
markings on it to aid in application and removal.
19. The fastener of claim 1 in which a predrilled void is provided
so that the fastener can be temporarily used as a jig to position
nails or screws that will be toenailed through the movable wall's
top or bottom plate or end studs into a fastener.
20. The fastener of claim 1 in which one or more voids is
predrilled laterally through the fastener so that it can be used to
attach a wall flush against another wall at the wall's bottom plate
so that finished flooring isn't damaged or top plate so that the
finished ceiling isn't damaged.
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to fasteners for a movable
wall, and more particularly, to wood fasteners that facilitate
detaching an interior nonbearing wall and reattaching the same wall
in a new position, thus avoiding both demolishing of existing walls
and building of new ones during a remodeling project.
BACKGROUND
[0002] Home remodeling projects generally involve demolishing walls
and building other walls. This work has several drawbacks: it
requires several weeks or months to complete; it requires
substantial cost; it requires skills many homeowners typically
don't have including mitering trim, squarely framing walls and
smoothly finishing gypsum; it involves substantial dust from
sawing, sanding and demolition; it produces substantial debris
which regulations may prevent from being conveniently thrown away
in household garbage; it leads to incidental marring of gypsum and
trim, soiling of carpets, denting of doors, breaking of protruding
lighting, cracking of driveway concrete, and scratching of
vehicles. In addition, the projects may have to be unexpectedly
stopped or altered because of hidden wiring, ductwork, plumbing or
other improvements which are not noticed until gypsum has been
removed.
[0003] Further, an increasing number of homeowners desire to be
"green" during home remodeling projects by eliminating some or all
of the demolition waste, component packaging, and component
manufacturing energy.
[0004] Further, home builders warrant the homes they build to
induce buyers to purchase the homes and so that lenders will
provide financing to the homeowners. It is therefore advantageous
to use materials whose performance characteristics home builders
are already familiar with. The most common materials used in
building interior nonbearing walls are wood studs, gypsum, nails
and screws.
[0005] Systems of movable walls exist in offices, warehouses,
factories, and stadiums where frequent room reconfigurability is
desirable and where the cost of a movable wall system can be
justified by comparing it favorably to the expense of repeated
demolition and rebuilding along with the loss of use during the
remodeling. It is difficult to justify these systems in a home
environment where room reconfiguration happens much less frequently
and where it is desirable for the movable walls to be nearly
indistinguishable from gypsum-covered wood stud framed walls. All
of these systems have drawbacks related to use in a home
environment, including one or more of the following: they use
materials other than wood studs, gypsum, nails, screws, and wood or
composite trim; they make use of exposed tracks or channels or
runners or rails to guide their movement or to hold them in place;
they have exposed brackets, supports, edging or seams. Systems of
movable walls in prior art have disclosed components which include:
[0006] a. Specially-constructed panels or partitions or walls which
are connected with special fasteners. However, these have the
disadvantage of not being finishable so as to be indistinguishable
from other gypsum walls in the home. At minimum, seams between
panels are apparent, and when those seams are filled with joint
compound, their ability to be detached without demolition is
defeated. [0007] b. Ceiling or floor tracks which guide and hold
panels. The exposed tracks are undesirable in a home environment
and the substantial metal in the track and connecting components
significantly increases the energy required to build the wall
system because of operations involved in mining, smelting,
manufacturing and transporting metal. [0008] c. Hinges, brackets,
edging, floor supports and ceiling supports can be used to
facilitate the attachment and construction of walls. However, these
have the disadvantage of having exposed parts which are not easily
finishable at home and which may corrode or become marred over
time.
[0009] Gripping systems can be used to hold walls in place without
tracks as disclosed in U.S. Pat. Nos. 3,638,376, 4,103,463, and
4,205,498. However, the cost of manufacturing a gripping system
adds considerable cost to a wall structure.
[0010] Prefabricated wall systems exist to quickly attach
nonbearing walls to bearing walls as in U.S. Pat. No. 3,457,698.
However these systems do not provide for detachment without
substantial demolition of the gypsum wall covering on the
load-bearing walls.
[0011] Pressurized or compression wall systems are used in
apartment buildings where a tenant wants to divide the unit to
accommodate roommates. Because the landlord typically refuses to
allow modification of an apartment, a pressurized system is used
since it can later be removed without damaging finished surfaces
when the apartment lease ends. Walls can be prefabricated offsite
and carried into an apartment, which reduces installation time and
reduces noise and activities which disturb neighboring apartments.
Because elevators, hallways and room configurations limit the size
of a wall that can be moved into an apartment, wall panels are
built in small sections and positioned together to form larger
walls. The seams between sections are covered with trim, or can be
finished with joint compound. The sections can be framed from wood
or steel studs and covered with gypsum. The sections are held in
place by a variety of methods, all of which continually press the
sections into the ceiling, floor and other walls. This pressure
allows walls to remain in place without screws or nails.
Unfortunately, the pressurized wall system has several drawbacks.
The walls are built for a single location within a home, so they
cannot be repositioned in multiple preplanned locations. When walls
are not needed, there is no way to store them until needed again,
so they are typically demolished or removed from the home so that
doors, windows and can be trim are saved for future use. While the
pressure system does keep the walls in place, they generally do not
have the same strength as walls attached to the floor, ceiling and
other walls with nails or screws, so shelving cannot be attached
and lightweight doors may be required. Patent application
20080209827 teaches an example of this method.
[0012] Office partitioning systems exist to construct purely
temporary "cubicles" and furniture-like workstations exist, both of
which are not useful in relation to attaching and detaching walls
in a home environment not only because of their temporary nature
and but also because they are not made of stud and gypsum. A
variation of the temporary wall structure is disclosed in U.S. Pat.
No. 4,972,634 in which a wall is described as temporary and is
covered in paper or fabric, and unfortunately is also not useful as
a semi-permanent wall in a home environment.
[0013] U.S. Pat. No. 4,825,601 discloses a modular wall made of
channels and slots, which unfortunately cannot be finished to be
indistinguishable from a gypsum and wood stud wall.
[0014] U.S. Pat. No. 4,407,101 discloses a fastener which attaches
a wall to a floor and simultaneously bears its weight, but
unfortunately it is not additionally useful in its single form at
ceilings and adjoining walls.
[0015] U.S. Pat. No. 2,864,732 discloses bracing elements for
securing building components, but unfortunately the bracing
elements are exposed and visible outside the walls.
[0016] Prior art also concerns itself with clips used to secure
gypsum to underlying studs and to protect the edges of gypsum, but
because they do not facilitate the attachment or detachment of a
wall without the demolition of the joint compound between gypsum
sheets, they are not useful in relation to attaching and detaching
walls in a home environment.
[0017] The invention is directed to overcoming one or more of the
problems and solving one or more of the needs as set forth
above.
SUMMARY OF THE INVENTION
[0018] To solve one or more of the problems set forth above, in an
exemplary implementation of the invention, a wood fastener is
provided. The wood fastener comprises a wood unit having at least
one upper and one lower groove. The grooves are offset. The grooves
have sufficient depth and width to allow passage of a reciprocating
saw blade. The side ends are trimmed to mesh with furring strips.
The fastener includes one or more starter holes to facilitate use
by guiding placement and insertion of screws or nails. In use, the
fastener attaches a movable wall to a building structure. To
facilitate removal of the fastener for rearrangement of the wall,
nails or screws extending through the grooved sections of the
fastener may be cut using a reciprocating saw.
[0019] In view of the foregoing background, it is therefore an
object of the wood fastener to enable a conventional interior
nonbearing wall to be detached and reattached without substantial
demolition or construction.
[0020] It is a further object of a wall attachment system to
facilitate a home builder's ability to warrant new home
construction by avoiding introduction of new materials which would
otherwise require a lengthy and costly scientific material
analysis, and by a consequence of this object, using only materials
in a wood fastener and in the movable nonbearing walls which are
already found in a conventionally built interior nonbearing wall,
namely wood stud material, nails, screws, trim, gypsum and
conventional gypsum finishing materials.
[0021] It is a further object of a wall attachment system to allow
tradesmen to build movable nonbearing walls during new home
construction from wood studs and gypsum in a fashion similar to
conventional methods, so that minimal new skills are required.
[0022] It is a further object of a wall attachment system to
minimize the extra costs required to construct a house with
specific movable nonbearing walls which may later be moved.
[0023] It is a further object of a wall attachment system to enable
a majority of homeowners to detach and reattach walls when they are
skilled in basic sawing, drilling, nail and screw driving, and the
fishing and basic connecting of wiring to receptacles, lights and
switches, where the homeowner is allowed by regulation to do
so.
[0024] It is a further object of a wall attachment system to
eliminate the need to lay new carpeting, new finished wood
flooring, or other finished flooring material during a remodeling
project because the flooring installed during new construction
suffers so little damage during the remodeling project that it
requires only minor repair.
[0025] If is a further object of a wall attachment system to
facilitate the moving of movable nonbearing walls in one or two
days so that homeowners can remain resident in their homes and can
avoid removing furnishing and possessions into storage.
[0026] It is a further object of a wall attachment system to
require so little change in wall construction that homeowners
perceive little to no difference between detachable nonbearing
walls constructed using this invention and the same walls
constructed in the conventional undetachable fashion from wood
studs and gypsum.
[0027] It is a further object of a wall attachment system to avoid
the common practice of hauling away construction debris in a
garbage dumpster by reducing the debris so much that it will be
contained in one or several garbage bags.
[0028] It is a further object of the fastener to minimize
incidental damage to gypsum, flooring, and trim by eliminating or
minimizing the amount of demolished material that needs to be
carried out of the house and the amount of new material that needs
to be carried into the house.
[0029] It is a further object of a wall attachment system to
minimize or eliminate extra energy resources required to
manufacture and transport the fastener invention.
[0030] It is a further object of a wall attachment system to
utilize a wood fastener to be useful in a single form at the
ceiling, floor, and adjoining stationary walls, which requires, at
minimum, that a wood fastener has the ability not only to attach a
movable nonbearing wall to the floor, but also to bear the weight
of the movable nonbearing wall.
[0031] It is a further object of a wood fastening system to make
use of a reusable wood fastener in two successive applications:
first, when a nonbearing wall is constructed and attached, and
again, when it is has been detached and reattached a second
time.
[0032] It is a further object of a wall attachment system for a
homeowner to complete all wall reconfiguration remodeling tasks
that regulations allow them to perform without licensed tradesmen
in a manner which does not require access to attic space.
[0033] It is a further object of a wall attachment system to
provide a means to store movable nonbearing walls inside the house
when not required in a particular room configuration so that during
a later remodeling project they can again be used when
required.
[0034] These and other objects, features, and advantages of the
invention are provided by a wood fastening system making use of a
wood fastener with a unique shape. A wood fastener is a block of
wood having a specialized shape. Grooves make it possible to detach
a wood fastener by inserting a pry bar and prying, or by inserting
a saw blade and cutting the nails or screws. outed corners provide
notches to attach furring strips for gypsum. Predrilled holes
ensure nails or screws are driven at proper locations. An
accompanying method makes use of a plurality of wood fasteners to
attach a nonbearing wall to other walls, ceilings and floors. The
method provides for attaching a nonbearing wall in a temporarily
suspended state so that finished flooring material can be installed
in a continuous fashion underneath it.
[0035] There has thus been outlined, rather broadly, important
features of the invention in order that the detailed description
thereof that follows may be better understood, and in order that
the present contribution to the art may be better appreciated.
There are additional features of the invention that will be
described hereinafter and which will form the subject matter of the
claims appended hereto.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] The foregoing and other aspects, objects, features and
advantages of the invention will become better understood with
reference to the following description, appended claims, and
accompanying drawings, where:
[0037] FIG. 1A shows a front view of a first embodiment of a wood
fastener in accordance with principles of the invention; and
[0038] FIG. 1B shows a perspective view of the opposite side of a
first embodiment of a wood fastener in accordance with principles
of the invention; and
[0039] FIG. 1C shows a perspective view of a first embodiment of a
wood fastener in accordance with principles of the invention;
and
[0040] FIG. 1D shows a section (B-B) [FIG. 1C] view of the opposite
side of a first embodiment of a wood fastener in accordance with
principles of the invention; and
[0041] FIG. 1E shows a section (A-A) [FIG. 1B] view of a first
embodiment of a wood fastener in accordance with principles of the
invention; and
[0042] FIG. 1F shows a perspective section (A-A) view of the
opposite side of a first embodiment of a wood fastener in
accordance with principles of the invention; and
[0043] FIG. 1G shows a section (C-C) [FIG. 1B] view of a portion of
a wood fastener in accordance with principles of the invention;
and
[0044] FIG. 1H shows a perspective section (C-C) [FIG. 1B] view of
a portion of a wood fastener in accordance with principles of the
invention; and
[0045] FIG. 2 shows a series of wood fasteners in accordance with
principles of the invention; and
[0046] FIG. 3A shows a side view of a wood fastener connecting a
movable nonbearing wall to a perpendicular stationary wall in
accordance with principles of the invention; and
[0047] FIG. 3B shows a side view of a wood fastener connecting a
movable nonbearing to the bottom plate of another wall sandwiched
next to the movable wall, by which fastening method a movable wall
is stored when not required in accordance with principles of the
invention; and
[0048] FIG. 4A shows a perspective view of a detachable wall
attached perpendicular to two parallel stationary walls and also to
a floor and ceiling by use a plurality of wood fasteners in
accordance with principles of the invention; and
[0049] FIG. 4B shows how ladder bracing is inserted into adjoining
stationary walls and ceiling where wood fasteners can be attached
to support a movable wall in accordance with principles of the
invention; and
[0050] FIG. 5A shows a top view of two closets made of detachable
walls joined by a plurality of wood fasteners into a configuration
of closets. in accordance with principles of the invention; and
[0051] FIG. 5B shows a top view of a set of walls joined by a
plurality of wood fasteners into a second configuration of closets.
in accordance with principles of the invention; and
[0052] FIG. 6A. shows a side view of a wood fastener attached using
a "toenailed" screw to a ceiling and how a wood fastener is used
temporarily as a jig to correctly position and the screw in
accordance with principles of the invention; and
[0053] FIG. 6B shows a side view of a wood fastener attached using
a "toenailed" screw to a floor and how a wood fastener is used
temporarily as a jig correctly position and the screw in accordance
with principles of the invention; and
[0054] FIG. 6C shows a top view of a wood fastener attached using a
"toenailed" screw to an adjoining wall and how a wood fastener is
used temporarily as a jig correctly position and the screw in
accordance with principles of the invention; and
[0055] FIG. 6D shows a side view of a wood fastener attaching two
end-to-end coplanar walls in accordance with principles of the
invention; and
[0056] FIG. 7 shows how notches in a wood fastener allow furring
strips to connect wood fasteners so gypsum can be further attached
to the furring strips instead of the fasteners in accordance with
principles of the invention; and
[0057] FIG. 8 shows how the second embodiment of a wood fastener
can be used without furring strips, thus avoiding labor during new
construction in accordance with principles of the invention;
and
[0058] FIG. 9 shows how the second embodiment can be cut to avoid
crown trim and base trim and an electrical receptacle which feeds
electrical cable into the movable wall in accordance with
principles of the invention; and
[0059] FIG. 10 shows a suspended movable wall with flooring
installed beneath the wall in accordance with principles of the
invention; and
[0060] FIG. 11 is a perspective view that conceptually illustrates
cutting of a nail that secures a wall to a fastener according to
principles of the invention.
[0061] FIG. 12 shows how trim and casing on stationary walls will
not interfere when a movable wall is moved from one position to
another in accordance with principles of the invention; and
[0062] FIG. 13 shows a movable wall's trim which has been routed to
complement the profile of a stationary wall's trim so that the
movable wall can be positioned anywhere along the stationary wall
in accordance with principles of the invention; and
[0063] FIG. 14 shows the side view of a large space, highlighting
that a wall can be moved only to other positions where the ceiling
height is the same in accordance with principles of the invention;
and
[0064] FIG. 15A shows a top-view example of where to position
electrical components to be useful in an example three-room
configuration in accordance with principles of the invention;
and
[0065] FIG. 15B shows how the same electrical components in FIG.
16A is useful without moving in an example two-room configuration
in accordance with principles of the invention; and
[0066] FIG. 16A shows atop-view example of where to position HVAC
ducts and return air ducts in an example three-room configuration
in accordance with principles of the invention; and
[0067] FIG. 16B shows how the same HVAC ducts and return air ducts
in FIG. 17A are useful without moving in an example two-room
configuration in accordance with principles of the invention;
and
[0068] FIG. 17A shows how fire and safety systems are laid out in
an example three-room configuration in accordance with principles
of the invention; and
[0069] FIG. 17B shows how the same fire and safety components in
FIG. 18A are useful without moving or adding in an example two-room
configuration in accordance with principles of the invention;
and
[0070] FIG. 18A is a top view of a movable wall and a stationary
wall showing how an electrical cable connects the movable wall to
the stationary wall in accordance with principles of the invention;
and
[0071] FIG. 18B shows an alternate way electrical receptacles in a
movable wall are wired together and can be easily connected to
house wiring by fishing a "pigtail" wire from the movable wall into
a ceiling electrical receptacle directly above the movable wall in
accordance with principles of the invention; and
[0072] FIG. 18C looks up at the ceiling above a movable wall
showing how a "pigtail" wire from a movable wall travels through an
electrical receptacle directly above a movable wall and then
through conduit to a second electrical receptacle in a ceiling in
which wires can be spliced and remain accessible in accordance with
principles of the invention; and
[0073] FIG. 19 shows how gypsum only extends to the outer edge of a
movable wall frame and the gaps to the adjoining wall and floor are
covered by trim in accordance with principles of the invention;
and
[0074] Those skilled in the art will appreciate that the figures
are not intended to be drawn to any particular scale; nor are the
figures intended to illustrate every embodiment of the invention.
The invention is not limited to the exemplary embodiments depicted
in the figures or the types of walls, wall structures, shapes,
relative sizes, ornamental aspects or proportions shown in the
figures.
DETAILED DESCRIPTION
[0075] The present invention will now be described more fully
hereinafter with reference to the accompanying drawings, in which
embodiments of the invention are shown. This invention may,
however, be embodied in many different forms and should not be
construed as limited to the embodiments set forth herein. Rather,
these embodiments are provided so that this application will be
thorough and complete, and will fully convey the true scope of the
invention to those skilled in the art. Like numbers refer to like
elements throughout the figures. In general, a wood fastener
according to principles of the invention comprises a wood unit
having at least one upper and one lower groove. The grooves are
offset. The grooves have sufficient depth and width to allow
passage of a reciprocating saw blade. The side ends are trimmed to
mesh with furring strips. The fastener includes one or more starter
holes to facilitate use by guiding placement and insertion of
screws or nails.
[0076] A wood fastener, shown in FIGS. 1A-1F, is made of wood stud
stock without significant defects such as cracking, warping or
knots which would impair its performance. The overall height, b, is
about 1.5 inches. The overall length, d, is about 8 inches, with
the length, e, of the medial section being about 6 inches. The
overall width, f, is about 3.5 inches. The width, g, of each side
is about 2 inches. The length, i, of each side is about 1 inch. The
depth of each groove 105, 106, 107 is about 0.25 inches. The width,
a, of each groove 105, 106, 107 is about 2 inches. This width is
preferably at least twice the width of a typical saw blade plus the
diameter of the shank of a nail (or screw), allowing a saw blade to
enter the space defined by the groove and cut a nail (or screw)
extending through such space, no matter where the nail passes
through that space. Materials other than wood stock, including
non-wood materials, may be used without departing from the scope of
the invention. Additionally, the dimensions may vary from the
exemplary dimensions described herein.
[0077] The wood fastener 100 generally comprises a rectangular
parallelepiped solid wood object bounded by six square faces,
facets or sides, with three meeting at each vertex. Various
grooves, cutouts, slots and holes are formed in the object by
cutting, drilling, routing and/or other woodworking operations.
[0078] Conspicuously, at least one groove 107 is formed on a first
side of the fastener 100. At least one groove 105, 106 is formed on
the opposite side of the fastener 100, not in alignment with the
groove 107 on the first side. In the exemplary embodiment, three
grooves 105-107 are shown, with one groove 107 approximately
centered, and the other two grooves 105, 106, offset from groove
107.
[0079] Another conspicuous feature of the exemplary fastener is a
plurality of cutouts (aka "notches") at corners of the fastener.
The cutouts 35, 40, 45 and 50 are configured to facilitate abutting
and partially overlapping furring strips. In construction, furring
strips are long thin strips of wood or metal used to make backing
surfaces to support the finished surfaces in a room. Furring strips
typically measure nominally 1''.times.2''. In a preferred
embodiment, the cutouts are about either 1''.times.1'' or
1''.times.3/4'' and extend the entire height of the fastener 100.
The cutouts are formed at the sides of the fastener by cutting
material from four corners of the wood stud stock from which the
fastener is formed.
[0080] Formation of the cutouts produces tab-like projections 10,
15, at each side end of the fastener. The tabs 10, 15 are centered
and include a centerline or slit for alignment. The tabs provide a
structure that can abut furring strips in certain
installations.
[0081] A plurality of wood fasteners 101 is used to attach a
nonbearing wall 138 to other walls 134 and 135, ceilings 136 and
floors 16 as shown in FIG. 4A. Wood fasteners are positioned at
intervals where the nonbearing wall adjoins other walls, ceilings
or floors. When all wood fasteners have been attached using nails
or screws both to the nonbearing wall and to the other adjoining
walls, ceiling, and floor the nonbearing wall is securely in place.
It has been discovered that using a plurality of wood fasteners in
this arrangement allows walls to be attached, detached, and reused
with little to no damage to the movable walls or to the adjoining
walls, ceiling and floor.
[0082] Before a wood fastener is attached to a nonbearing wall, it
is attached to the adjoining wall, ceiling, or floor by use of a
nail or a screw. As shown in FIG. 6A, when a wood fastener 101 is
used at the ceiling, the nail or screw 133 travels through a wood
fastener 101 and then through the ceiling's gypsum 125 and finally
into the underlying wood joist 128. As shown in FIG. 6B, when a
wood fastener 101 is used at the floor, a nail or screw 133 travels
through a wood fastener 101 and then through the adjoining flooring
127. As shown in FIG. 6C, when a wood fastener 101 is used at an
adjoining perpendicular wall, a nail or screw 133 travels through a
wood fastener 101 and then through the adjoining wall's gypsum 126
and finally into "ladder" bracing 182. The perpendicular wall shown
in FIG. 6C can be either a stationary conventionally framed wall or
a movable nonbearing wall. 6D, when a wood fastener 101 is used at
the floor where two coplanar walls meet, a nail or screw 133
travels through a wood fastener 101 and then through the adjoining
flooring 127. Two nails or screws are toenailed following path 132
into the two bottom plates 156 of the two walls and then into the
wood fastener 101. FIG. 1A shows a predrilled hole 108 which
facilitates the correct positioning of said nail or screw 133 in
FIG. 6A. FIG. 1A also shows a second predrilled hole 109 which is
provided so a wood fastener can be used a second time in a later
application. Predrilled holes 108 and 109 shown in FIG. 1A are
arranged 1.75 inches from the edge of a wood fastener and one inch
apart and penetrate a wood fastener to a depth of 1.25 inches.
These holes guide nails or screws through the fastener. To reduce
the probability that the fasteners will be incorrectly used, the
holes 108 and 109 do not fully penetrate the fastener until a nail
or screw is driven through them into an adjoining wall, ceiling or
floor. These two predrilled holes 108 and 109 are at a slight three
degree angle from perpendicular but remaining in the plane created
by joining the 115 marks. It has been discovered that this slight
angle will reduce the chance that the fastener will spin after it
has been attached to an adjoining wall, but before it is attached
to the stationary wall. The angle is so slight that a user will not
generally notice it and be tempted to correct it to be perfectly
perpendicular.
[0083] A wood fastener is attached to a non-bearing wall by driving
a nail or screw at an angle 132 (commonly called "toenailing") as
shown in FIG. 6A through a nonbearing wall's gypsum 144 and then
into its top plate 130 and then into a wood fastener 101 which is
in turn attached through ceiling gypsum 125 to a joist 128. In most
cases, a screw is preferred because it can be unscrewed when a wood
fastener is later detached. However, a nail is an option in all
cases, and is preferred when a wood fastener is used at the floor
where a screw would more severely damage finished wood flooring or
would spool up carpeting material as it twists into the
subfloor.
[0084] Without sacrificing it, a second wood fastener 131 can be
used as a temporary jig while attaching a wood fastener 101 as
shown in FIG. 3A. A predrilled hole 132 in the jig facilitates the
positioning of the toenailed nail or screw that attaches a wood
fastener 101 to the nonbearing wall stud 130. This predrilled hole
110 begins on one side of a wood fastener as shown in FIG. 1A,
travels into a wood fastener at an angle 106 shown in FIG. 6A and
until it almost penetrates the other side. To use the jig, insert a
6 inch drill bit into the predrilled hole 110 and drill through the
other side of the fastener and continue drilling into the wall's
gypsum 130, top plate 130 and fastener 101. The predrilled hole 132
does not initially penetrate the wood fastener to reduce the
probability that a user will not incorrectly position the jig.
[0085] As shown in FIGS. 1A-1D, groove 105 is routed to a depth of
3/16 inch and a width of two inches. This groove enables a saw
blade to be inserted on either side of a nail or screw 132 to cut a
wood fastener away from an end stud 157 in a detachable wall. After
all of these nails or screws have been cut on all wood fasteners
surrounding a nonbearing detachable wall, the wall is unsecured
from its adjoining walls, ceiling, and floor. Groove 106 is
identical to groove 105 and is used to cut a nail or screw when a
wood fastener is used a second time and in cases where two coplanar
nonbearing walls are both attached to the wood fastener.
[0086] As shown in FIGS. 1A-1D, groove 107 is routed to a depth of
1/4 inch and a width of two inches. When a screw has been used to
attach a wood fastener to the wall, ceiling, or floor that adjoins
the nonbearing wall it can be removed by unscrewing it. However,
when a screw's head has stripped, or when a nail has been used
instead, a wood fastener can be unattached by inserting a pry bar
into groove 107 and applying leverage. Alternatively, the groove
can be used to insert a saw blade to cut the nail or screw if
attempts to pry and unscrew fail.
[0087] As best illustrated in FIG. 11, the slots allow a cutting
tool (e.g., reciprocating saw blade 530) to access and sever a nail
535 (or screw) that secures a wall structure (e.g., sheetrock or
gypsum 510) to another supporting structure. In this embodiment,
the supporting structure is a wall comprised of studs 500 with
sheetrock or gypsum 505 attached thereto. The fastener 100 is
attached to the supporting structure by nails 515, 520. Upon
cutting the nail 535 that secures the wallboard 510 to the fastener
100, the wallboard 510 may be removed and moved. It is the access
space provided by the groove 107 that enables access by a
reciprocating metal-cutting saw blade for cutting. In a preferred
implementation only one nail or screw extends through the space
defined by the groove. However, if more than one nail or screw is
used, they should be arranged so that sufficient space is available
to accommodate the reciprocating saw blade.
[0088] By running a router along the edge 113 of a wood fastener as
shown in FIG. 1A a portion of a wood fastener has been removed to
act as a guide for the non-bearing wall as it is being moved into
position with a wood fastener. Similarly, as shown in FIG. 1B, a
second guide 114 has been routed into the other edge of a wood
fastener so a wall can be moved into position on a wood fastener
from either direction.
[0089] As shown in FIG. 7, 1 inch by 3/4 inch notches 159 are cut
away from a wood fastener so that furring strips 1 60 can be
attached from one wood fastener to another. Gypsum 143 and 144 can
then be attached to these furring strips instead of directly to
wood fasteners 1, so that nails or screws used to attach gypsum do
not have to be removed from wood fasteners before they are reused
later in a second application. The notches are also shown in FIG.
1A where edge 215 is 1 inch and edge 216 is 3/4 inch.
[0090] A nonbearing wall can be stored flush against another wall
in a sandwiched fashion when it is not in use. When this occurs, it
is desirable not to damage the finished flooring or finished
ceiling, and instead, to attach the movable nonbearing wall to the
adjoining wall's sole plate and top plate. A wood fastener provides
for this, as shown in FIG. 3B, by driving a lag screw along a path
162 from a wood fastener 101 and then into an adjoining wall's sole
plate 161 or top plate. As shown in FIGS. 1A, 1G and 1H, a
predrilled hole 112 is positioned in the wood fastener parallel to
edge 104. As shown in FIG. 24C, the hole is comprised of a section
countersunk to a depth of 3/4 inch 112B and second section 112A
which penetrates the wood fastener to a depth of 3 inches. The
diameter of the countersunk section is wide enough to insert a
ratchet to turn a screw with a hexagonal head. To reduce the
probability that the wood fastener will be incorrectly used, the
hole 112 does not fully penetrate the fastener until a screw is
driven through it to fasten one wall to another.
[0091] A wood fastener is manufactured using the common woodworking
techniques of sawing, routing, drilling and sanding, all of which
could be accomplished in small batches on the home site or in
larger batches in a milling factory. When very large fastener
quantities are desired, a CNC machine may be programmed to
automatically complete routing and drilling.
[0092] A wood fastener has two marks 115 as shown in FIG. 1A to
facilitate its quick placement on the wall, ceiling, or floor
adjoining the nonbearing wall where a line has been drawn marking
studs or bracing behind the gypsum to which the fastener
attaches.
[0093] FIGS. 5A and 5B show how walls which are attached with a
plurality of wood fasteners can be detached and reattached in
different configurations. FIG. 5A shows two rooms 150 and 151
separated by closets 152 and 153. The closets are made of seven
walls 141 (2), 139 (4) and 140 (1) which are attached to each other
with a plurality of wood fasteners. Doors 142 and 153 are also
shown. FIG. 5B shows how the seven walls have been reattached using
a plurality of wood fasteners to create a walk-in closet 154 for
room 150 and that room 151 is now without a closet.
[0094] Ceilings are framed at the same height wherever interior
walls can attach. They are finished without ornamental design, so
as to be easily repaired. FIG. 13 shows that a movable nonbearing
wall positioned at 166 dining new construction can be moved to a
position 167 during a remodeling project because the ceiling 136 is
the same height but cannot be moved to position 160 because the
ceiling height increases or to position 169 because the floor 137
steps down.
[0095] In the first embodiment described so far, separate wood
fasteneres are used and are connected by flurring strips as shown
in FIG. 7. However, a second embodiment, as shown in FIG. 2, is an
eight foot long 2.times.4 inch wood stud. Where all cuts, routings
and drilled holes heretofore described are repeated at 24 inch
intervals along the stud. In this embodiment, four wood fasteners
101 are embedded into the stud with 16 inches of stud material 123
between them, rather than being separate individual wood blocks.
Using this embodiment enables the entire fastening system to be
quickly positioned on the walls and floors adjoining the nonbearing
wall by simply cutting the stud to the proper length or positioning
multiple studs end to end. The second embodiment does not requite
flaring strips since gypsum can be attached directly to the stud
material between the wood fasteners as shown in FIG. 8. To cater
for eight foot ceilings, the second embodiment is extended on the
ends with 3.5 inches of stud material 209 on one end and 12.5
inches of stud material 155 on the opposite end.
[0096] FIG. 9 shows how the second embodiment can be cut to avoid
obstacles. In this example, the second embodiment is used between a
moving wall and an adjoining wall. Stud material 155a has been cut
to allow room for crown trim 149 at the ceiling. The bottom wood
fastener 101 has been cut from the second embodiment and placed
individually between an electrical receptacle 154 and base trim
146. Stud material 209 shown in FIG. 8 is discarded.
[0097] The second embodiment of the wood fastener can be
manufactured to any length, repeating the pattern of embedded wood
fasteners and stud material at whatever intervals the home builder
desires.
[0098] In walls that are taller or longer than the length of the
second embodiment of a fastener, the remainder of the wall can be
attached by using a plurality of the second embodiment of a
fastener, or by using both the first and second embodiments of a
fastener to achieve the required length.
[0099] In the second embodiment, embedded wood fasteners can be cut
on-site from the stud to create the individual wood fasteners
identical to the first embodiment shown in FIG. 1A.
[0100] A third embodiment is an embodiment made of a block of
engineered wood product, which otherwise has the same shape as and
is used in exactly the same fashion as the first or second
embodiment.
[0101] A fourth embodiment is an embodiment made of engineered wood
product, which otherwise has the same shape as and is used in
exactly the same fashion as the first or second embodiment.
[0102] A fifth embodiment is an embodiment made of medium-density
fiberboard (MDF), which otherwise has the same shape as and is used
in exactly the same fashion as the first or second embodiment.
[0103] A sixth embodiment is an embodiment made of molded plastic,
which otherwise has the same shape as and is used in exactly the
same fashion as the first or second embodiment.
[0104] It can be appreciated that prior to the disclosure of a wood
fastener, walls could not be detached, moved and reattached without
demolishing and rebuilding them. An accompanying method is
hereafter disclosed which teaches features to be included in new
construction to enable later room reconfiguration, steps to follow
during new construction, and steps to follow during remodeling
projects.
[0105] When constructing a new building, incorporate the following
features that allow a homeowner to reconfigure it in a future
remodeling project.
[0106] An interior space is formed from stationary walls and has at
least two locations where nonbearing interior walls could be moved
to and attached to form rooms, closets or stub walls as desired.
The example shown in FIG. 15 shows a large space which is divided
into two rooms 170 and 171, but which can be reconfigured during a
later remodeling project into three rooms by detaching two walls
172 and 173 built next two each other and attaching them in new
positions 172a and 173a.
[0107] One or more interior nonbearing walls are attached to
adjoining walls, ceilings, and floors by a plurality of wood
fasteners. These walls are constructed so as to have no plumbing,
ductwork, gas lines or wiring that adjoin other walls, ceiling, or
floor, other than as specific in the method described in the
present invention. They are constructed using conventional
techniques, except that their widths have been reduced to
accommodate wood fasteners and their heights have been reduced to
accommodate wood fasteners and finished flooring material.
[0108] When a space is divided during a remodeling project to add a
room, as is the case in the example illustrated in FIG. 15, a door
is required for the additional room. Conventional construction
during a remodeling project would require demolition of gypsum
beyond the desired doorway to install structural studs and a
header. To avoid this demolition, a doorway 218 is pre-framed
during initial construction with a sole plate and center stud to
attach gypsum, all of which can be knocked out when the doorway is
required during remodeling. During initial construction, tradesmen
avoid running wiring, plumbing or other improvement through the
pre-framed doorway so that no changes to the wiring or plumbing are
required during remodeling.
[0109] As shown in FIG. 14, crown trim 188, base trim 189, chair
rail trim 191, and window casement and sill 190 and other wall and
ceiling features are installed so that they protrude no more than
1.5 inches (the width of fasteners). This allows a wall, after
being detached from one position during a remodeling project, to be
moved past all wall and ceiling features to its new position.
Because the movable wall is moved off of the fasteners at the
floor, a three inch clearance exists above the top plate 130, which
allows crown trim 188 to be left in place on side walls 134 and
135.
[0110] Ceilings, stationary walls and floors are framed so as not
to warp over their expanses by more than one half inch every 10
feet so that a wall built during initial construction will fit in a
new location during a remodeling project.
[0111] All electrical receptacles on both sides of a movable wall
are wired together as shown in FIG. 19A. A cable 177 from all
electrical receptacles 212 in a movable wall 138 is connected to a
single receptacle 165 near a stationary wall. In this single
receptacle 165, an electrical cable 177 from all other outlets 212
in the movable wall is connected to a cable 176 that travels
through a conduit 174 in the movable wall, and then through a void
between wood fasteners 192 and then into a stationary wall 134, and
then into an electrical receptacle 164a on a stationary wall, and
then continues into a second conduit 214 and finally into another
receptacle 163 on a stationary wall where the cable is connected to
house wiring.
[0112] As an alternative to connecting a movable nonbearing wall's
receptacles to a cable extending from receptacle in a stationary
wall, the movable wall's receptacles may be connected to a
receptacle in the ceiling as shown in FIG. 19B. A cable 187
extending from the movable wall through its top plate 130 is fished
through a receptacle 184 in the ceiling directly above it. Because
regulations generally prevent cables from being spliced together
when not accessible, the cable is further fished, as shown in FIG.
19C, from the first receptacle 184 into a short piece of conduit
181 and into a second nearby ceiling receptacle 186 where it is
connected to house wiring 185. The first ceiling receptacle 184 is
concealed when the movable wall is in position, and is covered with
a plate when the movable wall is in another position. The second
ceiling receptacle 186 is always accessible and is covered with a
plate regardless of the movable wall's position.
[0113] Electrical outlets are wired so that their positions and
intervals are sufficient for all anticipated room configurations.
As shown in FIG. 16A, outlets in three rooms are installed in
positions where they will be useful without moving when a
remodeling project reconfigures the space to two rooms as shown in
FIG. 16B. Receptacles 164 are located on stationary walls in
positions where cable can be fished to movable walls and are used
as outlets when movable walls are not in position at them.
Electrical receptacles 213 in the movable walls in FIG. 16A are
disconnected when not required as shown in FIG. 16B.
[0114] Sufficient windows are installed to satisfy regulations for
any planned configuration, but which do not interfere with
predetermined wall locations. An example in FIG. 16A shows four
windows installed so that window 205 is in one room, window 206 and
207 are in a second room, and window 208 is in a third room.
However, after a remodeling project which reconfigures the three
rooms into two rooms, the four windows are still useful without
moving them. This is shown in FIG. 16B where the first new room has
two windows 205 and 206 and the second new room has two windows 207
and 208. The placement of the windows doesn't interfere with the
movable wall positions in either configuration.
[0115] Base and optional crown trim is installed as shown in FIG.
10 which is conventionally mitered in corners, but has square,
unmitered joins about one foot from the movable wall corners and
predetermined future wall positions, so that small pieces can be
removed when walls are moved and which can be reused without
additional mitering when the wall is reattached.
[0116] Two alternatives are provided to avoid mitering trim in
corners where movable walls meet stationary walls. First, as shown
in FIG. 11, plinths can be used. This alternative has the added
advantage of providing a square edge where optional vertical trim
can end. Second as shown in FIG. 12, base and optional crown trim
which runs along stationary walls can run without interruption from
one side of a movable wall to the other. At time of new
construction, the movable wall's trim is routed to exactly
complement the stationary walls trim profile. This allows the
movable wall's trim to be removed when the wall is detached and
then refastened to the movable wall after it has been reattached in
its new position.
[0117] Finished flooring material is installed so that it extends
under the movable wall to reduce flooring repair after the wall is
moved.
[0118] Gypsum is installed and finished as if the movable wall were
not in place so that when the movable wall is repositioned, the
gypsum on the ceiling and stationary walls are already in place and
finished, only requiring minimal repair.
[0119] Gypsum on the movable nonbearing wall is hung so that it
extends only so far as its top plate, sole plate, and end studs and
which is then covered at the edges with crown trim, base trim and
vertical trim. FIG. 4 shows how the movable wall's gypsum 143
extends to the edge of the movable wall's sole plate 156 and end
stud 145. Base trim 145 hides the gap between the movable wall's
gypsum and the floor 137. Vertical trim 147 hides the gap between
the movable wall's gypsum and the adjoining stationary wall 134.
Alternatively, gypsum on the movable wall can join with the
adjoining walls and then be finished in the usual way, thus
avoiding vertical trim 147. This alternative will require more
repair during a remodeling project.
[0120] An electrical receptacle 217 as shown in FIG. 16B is
positioned near a doorway with a cable extending to another
receptacle containing an electrical outlet. When a remodeling
project adds a room as has been done in the example where two rooms
in FIG. 16B have been reconfigured into three room in FIG. 16A, a
switch is installed in the receptacle 217. Alternatively, the
electrical receptacle can be connected to a ceiling electrical box
for a hanging ceiling lighting fixture.
[0121] No recessed ceiling lighting fixtures are installed, unless
the home has a programmable electrical switching system.
[0122] HVAC return ducts are installed for each room in each
possible room configuration. For example, return ducts are
installed so both configurations shown in FIG. 17A and FIG. 17B can
take advantage of the return ducts 211 without adding or moving the
ducts. In the case where a return duct is not needed in a specific
configuration, as shown in FIG. 17A, the return duct 211A is
installed with a damper which can be closed by removing the duct
grill and reaching inside.
[0123] HVAC vents are installed in a configuration appropriate in
each possible room configuration without adding or moving the
vents. For example, the small rooms in a configuration shown in
FIG. 17A are served by one or two ducts 210 each, whereas the two
larger rooms shown in FIG. 16B are served by three ducts each.
[0124] In the case where smoke detectors are connected
systematically, they are installed so their positions are
appropriate for any possible room configuration. A cover plate is
used when a receptacle for a smoke detector location is not in use.
For example, FIG. 18B shows a two room configuration where two
smoke detectors 221 and an unused receptacle with cover plate 222
are wired together. When a remodeling project reconfigures the
space to three rooms as shown in FIG. 18A, the cover plate is
removed on the receptacle and a third smoke detector is added,
without requiring rewiring the system or moving already-installed
smoke detectors.
[0125] In the case where fire irrigation is installed, the location
and number of irrigation heads should be sufficient for any room
configuration without moving or adding heads. FIG. 18A shows a
space configured with three rooms, and FIG. 18B shows the same
space configured after a remodeling project with two rooms. Fire
irrigation heads 220 and 220a are positioned in a way in which they
are useful without modification in either room configuration. 220a
is an example of a fire irrigation head which is installed at new
construction in a three-room configuration even though it is not
required until a remodeling project reconfigures the space into a
two room configuration where the room size has increased so much
that the diameter of the fire irrigation heads 220 will not fully
extend to protect the larger rooms.
[0126] Closets are constructed of a sufficient number for any
anticipated room configuration. Alternatively, closet walls are
attached by use of wood fasteners and are reconfigured as
necessary. As an example, FIG. 5A shows two rooms, 150 and 151,
each served by a closet. The closets are constructed from a
plurality of wall panels 139, 140 and 141 which are attached to
each other with wood fasteners. When room 151 is used as an office,
a remodeling project converts the two closets to a single closet by
moving the wall panels and reattaching them with wood
fasteners.
[0127] A movable wall is constructed with a top profile which
corresponds to the profile of a ceiling as shown in FIG. 23. In
example given so far, flat ceilings are illustrated. FIG. 23 shown
an example of a tray ceiling where a ceiling is higher in the
center of a room that at the edges of the room. To accommodate
profiled ceilings, movable walls are constructed to match the
ceilings profile so that at least one fastener can be inserted
between the movable wall's top plate and a ceiling at each change
in a ceiling's height. As shown in FIG. 23 a first embodiment of a
wood fastener is used at short segments of lower ceiling along the
edges of a room, and a plurality of wood fasteners is used along
the higher ceiling segment. Wood fasteners are not attached at the
vertical segments of ceiling where the ceiling height changes.
[0128] Construct bathrooms sufficient in number and size for any
anticipated room configuration.
[0129] When constructing a new building, ensure that a homeowner
will be able to reconfigure it without demolishing and rebuilding
walls by following these steps in order.
[0130] Step 1. Frame the floors, stationary walls, and ceiling, and
lay subflooring, if any, using conventional techniques.
[0131] Step 2. Use ladder bracing in walls and ceiling in each
position where a movable wall may be attached.
[0132] Step 3. Frame the movable nonbearing wall.
[0133] Step 4. Temporarily set aside the movable nonbearing wall
frame.
[0134] Step 5. Wire the electrical system in stationary walls and
the movable nonbearing walls. Leave the cable in the movable
nonbearing wall unconnected from house wiring. Order the electrical
inspection.
[0135] Step 6. Insulate where necessary and order an insulation
inspection. The movable nonbearing wall has been temporarily
positioned so as not to prevent insulation from being stapled in
the corners.
[0136] Step 7. Hang gypsum on the entire ceiling, and the exposed
face of the movable nonbearing wall, and the stationary walls,
except for those behind the temporary positions of the movable
nonbearing walls. The temporary position of the movable wall does
not to prevent sheets of gypsum from being attached above it.
[0137] Step 8. Finish all gypsum that has been thus far hung. The
movable nonbearing wall will prevent the far edges of the ceiling
from being finished until later.
[0138] Step 9. After examining them for defects, attach wood
fasteners as shown in FIG. 22 to the ceiling 198 and adjoining
stationary walls 199 and 200 where a movable nonbearing wall will
be positioned.
[0139] Step 10. Move the movable nonbearing wall 138 into position
as shown in FIG. 22 and lift it onto unattached wood blocks. While
holding the unattached movable wall 138 in place, insert shims 203
under the movable wall at the floor so that the top plate of the
movable wall abuts the wood fasteners on the ceiling 198.
[0140] Step 11. Attach the movable nonbearing wall 138 to the wood
fasteners at the ceiling 198 and adjoining stationary walls 199 and
200 as shown in FIG. 22.
[0141] Step 12. Connect the electrical cable in the movable
nonbearing wall to house wiring at the receptacle that was
installed for this purpose as shown in FIG. 16A.
[0142] Step 13. Attach furring strips wherever needed to attach
drywall and trim.
[0143] Step 14. Hang and finish gypsum on the end stationary wall
and the opposite sides of the movable nonbearing walls. Finish the
edges of the movable nonbearing wall with gypsum if desired.
[0144] Step 15. Remove the temporary blocks 203 shown in FIG. 22 at
the floor underneath the movable nonbearing wall 138 (FIG. 10) so
that the movable nonbearing wall 138 is suspended above the floor
137.
[0145] Step 16. Finish the floor as desired, ensuring the floor
material 202 shown in FIG. 22 runs underneath the movable
nonbearing wall 138. If carpeting is used, avoid carpet tack strips
at the edges of the movable nonbearing walls so that the carpet can
be more easily slipped under the suspended walls.
[0146] Step 17. Slide wood fasteners 204 shown in FIG. 22 into
place underneath the movable wall 138. Attach them through the
floor material by toenailing. Attach the movable nonbearing wall to
the wood fastener by toenailing.
[0147] Step 18. Attach base trim and any other desired trim.
[0148] When remodeling an existing building which has been built
using the method disclosed in this invention, follow these steps in
order.
[0149] Step 1. Turn off the electrical system and leave it off
until the project is complete. Remove window dressing, lighting
fixtures and other attached protrusions. Move and protect
furnishings. Protect the finished flooring.
[0150] Step 2. Locate the predetermined locations where the
nonbearing walls will be moved to and draw a pencil center line on
the ceiling, walls and floor. If the floor is carpeted, run a
string line instead.
[0151] Step 3. On the movable nonbearing walls where its gypsum is
finished to the ceiling or adjoining stationary walls, demolish
only so much gypsum as required to fully expose the wood fasteners.
Remove furring strips.
[0152] Step 4. On the movable nonbearing walls, carefully pry off
any trim and remove furring strips.
[0153] Step 5. If an electrical cable travels into the movable
nonbearing wall, disconnect it.
[0154] Step 6. If needed, cut the gypsum away from the doorway
which has already been framed. Remove the temporary stud and sole
plate.
[0155] Step 7. Using additional people to safely support the wall,
cut the movable wall free from the wood fasteners. Move the wall
toward the new location.
[0156] Step 8. Remove the wood fasteners from their positions at
the old wall location by prying nails as carefully as possible
without damaging gypsum or by unscrewing screws or as a last resort
by cutting the nails or screws using the groove provide in the wood
fastener.
[0157] Step 9. After examining them for defects, attach wood
fasteners at the new wall location where pencil or string lines
were marked. Position them so that the wood fasteners are centered
on the pencil or string line. At the ceiling and walls, attach the
wood fasteners through the gypsum to the underlying structural
material. At the floor, attach them through carpet or vinyl to the
subfloor, or directly to finished floor material.
[0158] Step 10. Move the nonbearing wall to the new predetermined
wall position and onto the wood fasteners.
[0159] Step 11. Tamp shims between the movable walls and wood
fasteners where needed for a tight fit, but don't rely on them to
hold the wall in place.
[0160] Step 12. Attach the movable nonbearing wall to the wood
fasteners through the movable wall's gypsum using the predrilled
jig in a spare wood fastener.
[0161] Step 13. Attach the movable nonbearing wall's electrical
cable.
[0162] Step 14. If an additional room has been created during the
remodeling project, provide lighting by installing and connecting a
switch to the wall electrical receptacle and cable already
installed and further connect them to an outlet or ceiling lighting
fixture to which the pre-installed cable extends. In addition, open
the damper for the return air vent, install a smoke detector in the
prewired receptacle, and install a new door and casement in the
preframed doorway.
[0163] Step 15. If a room has been eliminated during the remodeling
project, disconnect its lighting by removing it's switch and
covering the electrical boxes with plates. In addition, close the
damper for the return air duct, remove the smoke detector and cover
its electrical receptacle with a plate. Finally, remove the door,
install a sole plate and center stud in the doorway, and hang and
finish gypsum on both sides.
[0164] Step 16. Tack furring strips as needed to adjoining
stationary walls and ceiling to attach gypsum or trim.
[0165] Step 17. Attach base trim, optional crown trim and vertical
trim at the edges of the movable nonbearing wall. Alternatively,
attach gypsum at the ceiling and walls and finish it with joint
compound. If an additional room has been created, use plinths in
the corners to avoid mitering.
[0166] Step 18. Repair flooring if necessary.
[0167] Step 19. Reattach lighting and reinstall window
dressing.
[0168] Step 20. Test the electrical, HVAC, fire and safety and
other affected systems.
[0169] While an exemplary embodiment of the invention has been
described, it should be apparent that modifications and variations
thereto are possible, all of which fall within the true spirit and
scope of the invention. With respect to the above description then,
it is to be realized that the optimum relationships for the
components and steps of the invention, including variations in
order, form, content, function and manner of operation, are deemed
readily apparent and obvious to one skilled in the art, and all
equivalent relationships to those illustrated in the drawings and
described in the specification are intended to be encompassed by
the present invention. In particular, with respect to the above
description, it is to be realized that the optimum dimensional
relationships for the parts of the present invention may include
variations in size, materials, shape, form, function and manner of
operation. The assembly and use of the present invention are deemed
readily apparent and obvious to one skilled in the art. In
particular, the dimensions of the fastener have been described for
use with 2.times.4'' stud material. However, dimensions can be
adjusted to complement 2.times.3'' or 2.times.6'' studs, or other
stud, wall covering, and floor covering dimensions. The above
description and drawings are illustrative of modifications that can
be made without departing from the present invention, the scope of
which is to be limited only by the following claims. Therefore, the
foregoing is considered as illustrative only of the principles of
the invention. Further, since numerous modifications and changes
will readily occur to those skilled in the art, it is not desired
to limit the invention to the exact construction and operation
shown and described, and accordingly, all suitable modifications
and equivalents are intended to fall within the scope of the
invention as claimed.
* * * * *