U.S. patent application number 13/041172 was filed with the patent office on 2012-09-06 for construction panel positioning and support system and tools.
Invention is credited to William Matthews.
Application Number | 20120222385 13/041172 |
Document ID | / |
Family ID | 46752415 |
Filed Date | 2012-09-06 |
United States Patent
Application |
20120222385 |
Kind Code |
A1 |
Matthews; William |
September 6, 2012 |
CONSTRUCTION PANEL POSITIONING AND SUPPORT SYSTEM AND TOOLS
Abstract
A construction panel positioning tool includes a ramp member
having a support platform to support a panel edge, and a downwardly
inclined ramp section configured to slidingly engage and guide a
panel edge placed thereon toward the support platform. A
stabilizing member coupled to the ramp member engages a structural
building component to support the ramp member in position. A
construction panel support tool includes a suspension frame having
guides that slidably engage a ceiling joist, and a support member
cantilevered thereto, which has a top surface spaced from the
bottom of a ceiling joist to provide clearance for a construction
panel. A system includes one or more of each tool. The positioning
tool(s) is/are installed to position and support a first panel
edge. The opposite panel edge is then lifted against the ceiling
and then supported by the support member of a support tool that is
moved into place.
Inventors: |
Matthews; William; (Alsea,
OR) |
Family ID: |
46752415 |
Appl. No.: |
13/041172 |
Filed: |
March 4, 2011 |
Current U.S.
Class: |
52/749.1 |
Current CPC
Class: |
E04F 21/185
20130101 |
Class at
Publication: |
52/749.1 |
International
Class: |
E04G 21/16 20060101
E04G021/16 |
Claims
1. A construction panel positioning tool to position and support at
least one edge of a construction panel relative to a panel
installation site, the positioning tool comprising: a ramp member,
having: a support platform disposed at an upper end thereof, the
support platform further including an upper surface configured to
receive and support at least an edge portion of a construction
panel; and a ramp section disposed adjacent the support platform
and extending downwardly at an angle therefrom, the ramp section
further including a substantially planar upper surface having an
upper edge in common with the upper surface of the support
platform, the upper surface of the ramp section being configured to
slidingly engage and guide an edge portion of a construction panel
placed thereon toward the support platform; and a stabilizing
member coupled to the ramp member and configured to engage a
structural component of a building structure, thereby supporting
the ramp member in a predetermined position relative to the
installation site.
2. The positioning tool of claim 1, wherein the upper surface of
the support platform is horizontally disposed when the stabilizing
member is engaged with the structural component.
3. The positioning tool of claim 1, wherein the angle of the upper
surface of the ramp section relative to the upper surface of the
support platform is within a range of 20 to 60 degrees.
4. The positioning tool of claim 3, wherein the angle of the upper
surface of the ramp section elative to the upper surface of the
support platform is within a range of 35 to 45 degrees.
5. The positioning tool of claim 1, wherein the stabilizing member
is coupled to the support platform.
6. The positioning tool of claim 5, wherein the common edge of the
upper surfaces of the ramp section and the support platform is a
forward edge of the upper surface of the support platform, and
wherein the stabilizing member includes a elongate vertical brace
extending downward from the support platform and having a rear
surface that is configured to engage a wall joist of the building
structure or a construction panel installed thereto.
7. The positioning tool of claim 6, further including one or more
rearwardly extending arms disposed on the vertical brace, the one
or more arms adapted to engage one or both sides of a wall joist of
the building structure.
8. The positioning tool of claim 5, wherein the common edge of the
upper surfaces of the ramp section and the support platform is a
forward edge of the upper surface of the support platform, and
wherein the stabilizing member includes one or more arms extending,
respectively, to one or both sides thereof.
9. The positioning tool of claim 8, wherein one or more of the arms
includes a vertically-disposed rear surface that is either even
with or protrudes rearwardly beyond a rearward edge of the upper
surface of the support platform and that is adapted to engage and
be temporarily secured to a wall joist of the building structure or
a construction panel installed thereto.
10. The positioning tool of claim 9, wherein the vertical brace
includes one or more tabs extending rearwardly therefrom and that
are adapted, respectively, to engage one or both sides of a wall
joist of the building structure.
11. The positioning tool of claim 5, wherein the common edge of the
upper surfaces of the ramp section and the support platform is a
forward edge of the upper surface of the support platform, and
wherein the stabilizing member includes an elongate horizontal
brace configured to extend generally rearwardly of the support
platform.
12. The positioning tool of claim 11, wherein the elongate
horizontal brace includes one or more horizontally-disposed upper
surfaces adapted to engage and be temporarily secured to a ceiling
joist of the building structure or a construction panel installed
thereto.
13. The positioning tool of claim 1, wherein the common edge of the
upper surfaces of the ramp section and the support platform is a
forward edge of the upper surface of the support platform, and
wherein the ramp section extends perpendicular to the forward edge
of the support platform.
14. The positioning tool of claim 1, wherein the ramp member is
hingedly coupled to the stabilizing member.
15. A construction panel support tool to temporarily support a
construction panel relative to a panel installation site, the
support tool comprising: a suspension frame adapted to movably
mount the tool on a ceiling joist, the suspension frame further
including elongate top and bottom guide members respectively
configured to slidably engage the top surface and the opposing side
surfaces, and the bottom surface, of the ceiling joist, wherein the
top and bottom guide members are coupled to maintain a
predetermined spaced relation therebetween; an elongate support
member coupled to the suspension frame and configured, when the
suspension tool is suspended from a ceiling joist, to extend away
from the suspension frame in a plane substantially parallel to, and
spaced below, that of the bottom surface of the ceiling joist.
15. The panel support tool of claim 15, wherein the top and bottom
guide members are adjustably coupled to allow adjustment of the
distance therebetween to thereby accommodate ceiling joists of
different heights.
17. The panel support tool of claim 15, wherein the elongate
support member extends away from the suspension frame substantially
parallel to a longitudinal axis thereof.
18. The panel support tool of claim 15, wherein the suspension
frame further includes one or more struts rigidly coupling the top
and bottom guide members, and wherein the elongate support member
is mounted to a portion of one or more of the struts that extends
below the bottom guide member.
19. The panel support tool of claim 15, wherein the elongate
support member is mounted for pivotable movement within a limited
range relative to the plane of the bottom surface of the ceiling
joist.
20. A construction panel support system to position and temporarily
support a construction panel relative to a panel installation site,
the panel support system comprising: one or more construction panel
positioning tools, each positioning tool further including: a ramp
member having a support platform at an upper end thereof configured
to receive and support a portion of a construction panel and a ramp
section adjacent the support platform and sharing a common edge
therewith, the ramp section including a substantially planar upper
surface configured to slidingly engage and guide a portion of a
construction panel placed thereon toward the support platform; and
a stabilizing member coupled to the ramp member, the stabilizing
member being configured to engage a structural component of a
building structure to support the ramp member in a predetermined
position relative to the installation site; and one or more
construction panel support tools, each support tool further
including: a suspension frame adapted to movably mount the support
tool on a ceiling joist, the suspension frame having elongate top
and bottom guide members configured to collectively slidingly
engage the top, bottom, and side surfaces of a ceiling joist; and
an elongate support member coupled to the suspension frame and
disposed to extend in a plane substantially parallel to, and spaced
below, that of the bottom surface of a ceiling joist to which the
support tool is movably mounted.
Description
TECHNICAL FIELD
[0001] The disclosure relates to building construction, and in
particular to tools to assist lifting and supporting construction
panels in position for installation.
BACKGROUND
[0002] In building construction in the U.S., it is conventional to
install sheets of drywall and other types of construction panels
(such as plywood, paneling, other forms of wall sheeting, and so
forth) to ceiling and wall joists. However, construction panels can
be large and somewhat cumbersome to position for installation.
Drywall, for example, is typically composed of a layer of crushed
gypsum pressed between two sheets of thick paper. A standard sheet
of drywall is usually 4' by 8', or 4' by 12', in size, and
generally weighs between about 50 to 110 pounds, depending on its
constituent materials and dimensions. When drywall and other
construction panels are installed to walls and ceilings, it is
often necessary for one or more workers to hold the panel in place
while others nail or screw it to the underlying joists or
supports.
[0003] Construction panel lifts, which are sometimes referred to as
drywall jacks in drywall-specific applications, are not
satisfactory for the range of applications in which they are
employed. For example, existing lifts generally include a number of
articulating components and/or are complex to maneuver and operate,
and in general are quite cumbersome. Further, some lifts do not
significantly decrease the labor expense of positioning by hand,
because many require one person to attend to the lift at all times
to maintain the construction panel in a desired position, while
another worker fastens the panel to the installation site. Lacking
a second worker, the use of conventional construction panel lifts
by a solo worker risks injury and/or inaccurate positioning or
installation of a panel.
SUMMARY
[0004] Illustrative embodiments of construction panel positioning
tools and construction panel support tools, and construction panel
positioning and support systems employing two or more of such
tools, are disclosed herein. An illustrative embodiment of a
construction panel positioning tool to position and support at
least one edge of a construction panel relative to a panel
installation site includes a ramp member and a stabilizing member
coupled thereto. The ramp member includes a support platform
disposed at an upper end thereof and having an upper surface to
receive and support at least an edge portion of a construction
panel, and a ramp section adjacent the support platform and
extending downward at an angle therefrom. The ramp section is
configured to slidingly engage and guide an edge of a construction
panel placed thereon toward the support platform, with which it
shares a common edge. The stabilizing member is configured to be
temporarily secured to or otherwise engage a structural component
of a building structure, such as a wall or ceiling joist, to
support the ramp member in position. In some panel tool
embodiments, the stabilizing member includes a vertical brace, such
as to engage and/or be secured to one or more wall joists, with the
ramp section projecting at an angle away from the wall joist. When
installed with the support platform near ceiling joists, such
embodiments may be used to position and then temporarily support an
edge of a construction panel in position for installation to the
ceiling joists. In some panel tool embodiments, the stabilizing
member includes a horizontal brace, such as to engage and/or be
secured to one or more ceiling joists.
[0005] An illustrative embodiment of a construction panel support
tool to temporarily support a construction panel relative to a
panel installation site includes a suspension frame and an elongate
support member coupled thereto. The suspension frame includes
elongate top and bottom guide members collectively configured to
slidably engage all four sides of a ceiling joist, and the support
member cantilevers away from the suspension frame, and includes a
top surface that is spaced, with respect to a ceiling joist with
which the suspension frame is engaged, to provide temporary support
of a construction panel to the ceiling joist.
[0006] in use, an illustrative embodiment of a construction panel
positioning and support system, which includes one or more
construction panel positioning tools and one or more construction
panel support tools, may be used, such as by an individual worker,
to assist in maneuvering and holding construction panels in
position for installation, for example to ceiling joists in order
to form a ceiling. For example, one or more panel positioning tools
with vertical stabilizing members may first be fastened to wall
joists so the support platforms are near the ceiling joists. A
construction panel, such as a sheet of drywall, may be placed with
a first or forward edge on the ramp section(s) of the positioning
tool(s) and slid upward so the forward edge is supported on the
support platform(s) thereof. With the forward edge supported, the
worker may lift the opposite edge toward the ceiling joists. A
panel support tool suspended on a nearby ceiling joist may then be
slid therealong so the support member extends below the
construction panel, providing vertical support so the worker can
then install the construction panel. The positioning tool(s) may
then be removed and the support tool moved away from the installed
panel. To install a second panel adjacent the first, a worker may
then fasten one or more panel positioning tools with horizontal
stabilizing members to the ceiling joists to which the first panel
is installed, and use the ramp sections of the positioning tools in
the same manner to raise and then support the forward edge of the
second panel in place, lifting the opposite edge up to the ceiling,
and holding the panel in place by sliding a support member of a
panel support tool underneath the panel.
[0007] The concepts and components listed above are clarified with
reference to the accompanying drawings and detailed description
below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows a three-dimensional view of a first
illustrative embodiment of a construction panel position tool
constructed in accordance with aspects of the present disclosure,
with a vertically-oriented stabilizing member that includes two
horizontal arms by which the tool is removably secured to a wall
joist.
[0009] FIG. 2 shows a front elevation view of the positioning tool
of FIG. 1.
[0010] FIG. 3 shows a three-dimensional view of a second
illustrative embodiment of a construction panel positioning tool
constructed in accordance with aspects of the present disclosure,
with a horizontally oriented stabilizing member by which the tool
is removably secured to a ceiling joist to which a construction
panel is installed.
[0011] FIG. 4 shows a front elevation view of the positioning tool
of FIG. 3.
[0012] FIG. 5 shows a three-dimensional view of an illustrative
embodiment of a construction panel support tool constructed in
accordance with aspects of the present disclosure, having a
suspension frame by which the tool is suspended from a ceiling
joist. An elongate support member extends partially beneath a
construction panel, supporting the panel beneath the ceiling
joist.
[0013] FIG. 6 shows a partial side elevation view of a construction
panel positioning tool, such as shown in FIG. 1, as part of a
construction panel positioning and support system, in which the
positioning tool is removably secured to a wall joist, and in which
a forward edge of a construction panel is shown to be guided upward
along the ramp section of the positioning tool.
[0014] FIG. 7 shows a side elevation view of the positioning tool
of the positioning and support system partially shown in FIG. 6, in
which the forward edge of the construction panel is shown to have
been guided onto the support platform of the positioning tool.
[0015] FIG. 8 shows a side elevation view of the positioning and
support system partially shown in FIGS. 6 and 7, now including a
construction panel support tool, shown to be moved so that the
elongate support member thereof extends beneath the construction
panel to support it in place for installation.
[0016] FIG. 9 shows a side elevation view of the positioning system
partially shown in FIGS. 6-8, now including a second construction
panel positioning tool, such as shown in FIG. 3, in which the
positioning tool is secured to the ceiling joist to which a
construction panel is installed, and in which a forward edge of a
second construction panel is shown to be guided upward along the
ramp section of the positioning tool.
DETAILED DESCRIPTION
[0017] A construction panel positioning and support system 50,
which includes one or more construction panel positioning tools
(indicated generally at 10) and one or more construction panel
support tools (indicated generally at 40), and example embodiments
of the individual tools thereof, is shown in FIGS. 1-9. As
described in greater detail below, the tools of the system are
collectively and individually adapted to assist a user in
maneuvering and/or temporarily supporting a construction panel,
such as a drywall sheet, in a desired position adjacent an
installation site, to which it may then be installed.
[0018] In general, the positioning tool(s) 10 are each adapted to
engage and/or be supported on a structural component of a building
structure, such as by being removably or temporarily secured to a
wall or ceiling joist, and/or a construction panel already
installed thereto. Once supported in place, the positioning tools
may facilitate guiding a first edge (also referred to herein as a
forward edge) of a construction panel, by means of an inclined ramp
section, and then temporarily supporting the panel edge on a
support platform in a desired position, such as adjacent to a joist
to which the panel will then be installed. The support tool(s) 40
are also each adapted to be supported on a structural component,
such as by being movably suspended from a ceiling joist, and may
facilitate supporting a portion of a construction panel, such as a
second edge of a construction panel partially supported on one or
more positioning tools, by being moved along the joist into a
position in which a support member engages the construction panel
portion. As such, the tools may be used separately, or collectively
as a system.
[0019] For ease of explanation, the illustrative embodiments of the
tools 10, 40 shown and described herein are adapted for use with
sheets of drywall to be temporarily supported in a generally
horizontal orientation adjacent ceiling joists, prior to
installation thereto. However, it will be clear from the following
description that the tools may be adapted for use with other types
of construction panels as well as drywall sheets, any of which may
be installed in a variety of orientations (such as vertical, such
as for installation to wall joists, or in an angled orientation,
such as for installation to joists or other structural beams or
supports forming curved or angled walls or ceilings), without
departing from the scope of the invention. As such, for example,
the directional terms used in the description below are relative
and are provided for the sake of clarity, and should not be
considered in a limiting sense.
[0020] Also, the illustrative tool embodiments shown and discussed
below are prototype embodiments fashioned from pieces of industrial
steel, such as square tubing and angle steel and so forth, which
have been rigidly welded together and/or machined to have the
particular characteristics explained herein. Moreover, the specific
dimensions, scale, and other measurements thereof are customized
for use with standard lumber sizes and construction techniques
conventionally used in building construction in the U.S. For
example, a wall frame is generally constructed from 2.times.4 beams
of lumber and/or steel braces, with a series of vertical beams
(studs) extending between horizontal top and bottom beams (plates).
Typically, there are two top plates, one on top of the other, with
a parallel series of 2.times.4 or 2.times.6 beams extending
edgewise across the top plates of opposing wall frames to form the
ceiling frame. However, the disclosure should be understood to
encompass embodiments that may be constructed to suit other
structural beam components or configurations, fabricated from other
suitable materials and assembled in other manners, and/or
configured to include adjustable or otherwise movable linkages
between or among various components and parts of the particular
tool.
[0021] Two illustrative embodiments of a construction panel
positioning tool 10 are discussed first with reference to FIGS.
1-4, followed by a discussion of an illustrative embodiment of a
construction panel support tool 40, with reference to FIG. 5. The
description then proceeds with a discussion of how the tools 10, 40
may be used together as a construction panel positioning and
support system 50, with reference to FIGS. 6-9, and concludes by
discussing some alternative configurations and/or variants of some
of the embodiments, such as to illustrate variations of structural
components and arrangement of such components. The various
embodiments, configurations, and methods disclosed in the
paragraphs below are illustrative and should not be considered in a
limiting sense, but merely for purposes of illustrating one or more
of the aspects of the subject matter described herein. Numerous
variations are possible and considered to be within the scope of
this disclosure.
[0022] A first, non-exclusive, illustrative embodiment of a
construction panel positioning tool 10 is shown in FIGS. 1 and 2 at
100, and a second, non-exclusive, illustrative embodiment is shown
in FIGS. 3 and 4 at 200. Both embodiments of positioning tool 10
are adapted to position and support an edge, or edge portion, of a
construction panel in a desired position, such as adjacent to an
installation site. In particular, positioning tools 100 and 200 are
both adapted to support a forward edge of a sheet of drywall in
position substantially adjacent to one or more ceiling joists to
which the sheet is to be installed. The structural differences
between the two illustrative embodiments provide configurations
that are each suitable for a different type of installation site.
More specifically, positioning tool 100 is an embodiment in which
the stabilizing member is adapted to engage a wall component, such
as one or more wall joists, and thus may be suitable for a ceiling
installation site in which one or more edges of a drywall sheet are
to be installed adjacent to a wall. Positioning tool 200, however,
is an embodiment in which the stabilizing member is adapted to
engage a ceiling component, such as a ceiling joist to which a
sheet of drywall has already been installed, and thus may be
suitable for a ceiling installation site in which none of the edges
of a dry all sheet will be adjacent to a wall.
[0023] In general and somewhat functional terms, each of the
positioning tool embodiments includes an elongate ramp member 12
coupled to a stabilizing member 14, which is configured to engage a
structural building component to thereby support the ramp member in
a predetermined position relative to an installation site on the
building structure. Ramp member 12 includes a support platform 16
disposed at its upper end, and a ramp section 18 disposed adjacent
the support platform 16 and configured to extend downwardly at an
angle therefrom. The ramp section 18 includes a substantially
planar upper surface 20 configured to slidably engage and
subsequently guide a forward edge of a construction panel placed on
the ramp section toward the support platform 16. The upper surface
of the ramp section has an upper edge 22 in common with an upper
surface 24 of the support platform 16, which is configured to
receive and support at least the forward edge of the construction
panel.
[0024] In more specific terms, as can be seen from FIGS. 1 and 2,
positioning tool 100 is shown to be constructed from two bars 102,
104 of square steel tubing, which are coupled at the upper ends
thereof to form an apex. In particular, the front bar 102 projects
forward at an acute angle relative to the rear bar 104, which is
shown to be vertically oriented. A crossbar 106, shown as a length
of angle steel, is coupled at its center to the apex to extend at
right angles to the vertical plane formed by bars 102, 104, with
its top plate 108 forming a horizontal plane and its side plate 110
abutting the rear side of the rear bar 104. The side plate 110,
which may be thought of as opposing arms extending to either side
of the rear bar, is provided with one or more openings 112, for
example so that fastening means (shown as screws S) may be used to
temporarily and removably secure the tool to one or more wall
joists W. The forward edge 114 of the top plate 108 is biased
across its thickness, and along its length, at the same angle at
which the front bar 102 projects, such that the upper surface 116
of the front bar has an edge 118 in common with the upper surface
120 of the top plate 106. Finally, the lower end of the rear bar
104 is shown to include a U-shaped brace member 122, which consists
primarily of a pair of parallel arms 124 that extend rearwardly
from a base plate 126 that is coupled to the rear side of bar 104.
As shown, parallel arms 124 are spaced from each other by a
distance sufficient to provide a clearance fit for a wall joist
W.
[0025] Thus, in the first embodiment 100, the top plate 108 of the
crossbar 106 provides the support platform 16 of the positioning
tool 10, with the upper surface 122 of the top plate forming the
upper surface 18 of the support platform adapted to receive and
support the forward edge of a construction panel such as a drywall
sheet. The upper surface 120 of the front bar 102 provides the ramp
section 18 of the tool, and the stabilizing member 14 is
collectively formed from the rear bar 102, the side plate 110, and
the brace member 122. More specifically, the rear surface of the
side plate 110 is positioned to abut a horizontal wall joist W, for
example a top plate, and be temporarily secured thereto, and the
brace member 122 engages the vertical wall joist W. As mentioned
above, but although not shown in this view, ceiling joists are
typically supported on the top plates, so the tool 100 is generally
installed in a position such that the upper surface 122 of the top
plate 108 is spaced from the ceiling joist sufficiently to
accommodate the thickness of a construction panel. In embodiments
that include a brace member, the tool is generally centered (or
otherwise positioned) relative to a stud (vertical wall joist W) so
that the arms of the brace member loosely engage either side of the
stud, such as to provide additional restriction of lateral movement
of the tool relative to the wall frame.
[0026] In prototype embodiments represented by the first
illustrative embodiment 100 of positioning tool 10, 3/4'' square
tubing was used for the front and rear bars, with the rear bar
having an overall length in the range of about 10'' to 18'', and
the front bar having an overall length in the range of about 18''
to 24''. The downwardly projecting tip of the front bar, in some of
the prototype embodiments, was smoothed or radiused on its upper
corner (as shown in FIGS. 1 and 2), and/or was bent to curve
further downward, to present a smoother surface to the drywall
sheet engaging the bottom end of the bar. Additionally, the angle
between the front and rear bars was in the range of about 45 to 55
degrees (resulting in the angle formed between the upper surface of
the ramp section and the upper surface of the support platform
being in the range of about 35 to 45 degrees). A length of
1''.times.1'' angle steel in the range of about 6'' to 10'' was
used for the crossbar. However, some variants were not provided
with a crossbar, instead having openings through the rear bar for
securement to a wall stud, and having support platform only as wide
as one or both of the front and rear bars. Also, some variants were
not provided with a brace member; in some applications, such as
those in which multiple positioning tools were installed in
parallel on a wall frame, to provide multiple points of support for
a drywall sheet placed thereon, the brace member was found not to
be as helpful to restrict lateral movement of the individual tools
as in applications in which only one positioning tool was used.
[0027] In FIGS. 3 and 4, the second illustrative embodiment 200 of
positioning tool 10 is also shown to be constructed from two bars
202, 204 of square steel tubing, coupled at the ends thereof to
form an apex, but with the front bar 202 projecting forward at an
obtuse angle relative to the rear bar 204, which is shown in this
embodiment to be horizontally oriented. The upper surface 206 of
the front bar has an upper edge 208 in common with the upper
surface 210 of the rear her 204. A brace 212, shown as an elongate
bar of angle steel, is coupled at its proximal end to the distal
end of the rear bar 204 and extends generally rearwardly therefrom
along a longitudinal axis parallel to that of the rear bar. Brace
212 consists of a side plate 214, the lower portion of which, at
the forward end thereof, is coupled to a side surface of the rear
bar 204, and a top plate 216, which is spaced upward from the upper
surface 210 of the rear bar by a distance sufficient to accommodate
the thickness of a forward edge of a construction panel. Top plate
216 is provided with one or more openings 218, for example so that
fastening means (shown as screws S) may be used to temporarily
secure the tool to one or more ceiling joists C, for example
through a construction panel P installed thereto.
[0028] In the second embodiment 200, the rear bar 204 provides the
support platform 16 of the positioning tool 10, with the upper
surface 210 thereof forming the upper surface 24 of the support
platform adapted to receive and support the forward edge of a
construction panel such as a drywall sheet. The front bar 202
provides the ramp member 12, with the upper surface 206 of the
front bar 202 providing the ramp section 18 of the tool. The
stabilizing member 14 is in the form of the brace 212.
[0029] In prototype embodiments represented by the second
illustrative embodiment 200 of positioning tool 10, 3/4'' square
tubing was used for the front and rear bars, with the rear bar
having an overall length in the range of about 2'' to 6'', and the
front bar having an overall length in the range of about 18'' to
24''. As with embodiment 100, the downwardly projecting tip of the
front bar, in some of the prototype embodiments, was smoothed or
radiused on the upper corner (as shown in FIGS. 3 and 4), and/or
was bent to curve further downward, and the angle between the front
and rear bars was in the range of about 135 to 145 degrees
(resulting in the angle formed between the upper surface of the
ramp section and the upper surface of the support platform being in
the range of about 35 to 45 degrees). A length of 1''.times.1''
angle steel in the range of about 10'' to 14'' was used for the
crossbar, with the length of the front end coupled to the side
surface of the rear bar being in the range of about 1'' to 4''. The
clearance between the upper surface of the rear bar and the top
plate was between about 1/4'' to 3/4''. In some variants, the
support platform was laterally extended by means of an additional
crossbar configured to extend to either side of the rear bar.
[0030] A non-exclusive, illustrative embodiment of a construction
panel support tool 40 is shown in FIG. 5 at 300. Briefly, the
support tool 40 is adapted to temporarily support an edge, edge
portion, or other portion of a construction panel P in a desired
position, such as adjacent to an installation site. In particular,
support tool 300 is adapted to movably mount to a ceiling joist C
and be selectively moved into place to support the lower surface of
a sheet of drywall in position substantially adjacent to one or
more ceiling joists to which the sheet is to be installed.
[0031] In general and somewhat functional terms, support tool 40
includes a suspension frame 42 adapted to movably mount the tool on
a ceiling joist C, and a support member 44 coupled thereto and
disposed to extend away therefrom in a plane parallel to that of
the bottom surface of the ceiling joist C to which the suspension
frame 42 is mounted.
[0032] More specifically, suspension frame 42 of support tool 300
is shown to be formed from elongate top and bottom guide members
302, 304 coupled to each other by means of struts 306. In
particular, top guide member 302 forms a channel adapted to provide
at least a clearance fit with the top edge of a ceiling joist C,
with the channel defined by parallel sidewalls 308 extending
downward from a top wall 310. Bottom guide member 304 includes a
sidewall 312 and a bottom wall 314 adapted, respectively, to engage
one side and the bottom edge of the ceiling joist C. This
configuration allows the entire frame 42 to be suspended from a
ceiling joist by "hanging" the top guide member over the top edge
at a slight angle, then engaging the bottom wall 314 with the
bottom edge of the joist. The struts maintain a predetermined
spaced relation between the top and bottom guide members.
Optionally, the guide members may be adjustably coupled, such as to
accommodate ceiling joists of different widths (for example,
2.times.8 s, 2.times.6 s, and 2.times.4 s are all lumber sizes that
are commonly used for ceiling joists). In support tool 300, the
adjustability is provided by means of openings along struts 306
through which bolts 316, which protrude from sidewall 312, may
extend and be fastened by means of nuts 318.
[0033] The support member 44 of support tool 300 is shown to be
formed from an elongate bar 320 of square steel tubing that
cantilevers in a direction parallel to a longitudinal axis of the
support frame, in a plane substantially parallel to, and spaced
below, the bottom surface of the ceiling joist. In particular, the
spacing is sufficient to accommodate the thickness of a
construction panel. Bar 320 is coupled to the suspension frame by
means of a pair of bolts 322, which protrude downward from bottom
wall 314, and which are fastened by nuts 324. Although not required
to all embodiments, this coupling is also shown in support tool 300
to be adjustable, such as to allow a user to adjust the clearance
between the top surface of the bar 320 and the bottom surface of
the ceiling joist C. The clearance may be determined by user
preference, thickness of the particular construction panel with
which the support tool is being used, and so forth, but is
generally a value greater than the thickness, but less than about
twice the thickness, of a construction panel.
[0034] In prototype embodiments represented by embodiment 300 of
support tool 40, a length of 1'' square tubing having an overall
length in the range of about 24'' to 30'' was used for the elongate
support bar. The top and bottom guide members both had an overall
length in the range of about 6'' to 10'', which was suitable to
prevent the suspension frame from rocking or tipping on the ceiling
joist when the weight of a sheet of drywall is supported by the
support bar.
[0035] In some prototypes, instead of bolts, one or both struts
extend beyond the bottom guide member to either adjustably (by
means of additional openings) or non-adjustably (such as by
welding) couple with the support bar. In one variant, the support
bar is mounted for a limited range of pivotal movement in a
vertical plane on one strut, and a biasing means in the form of a
tension spring positioned to bias the distal end of the bar upward,
for example to urge the end of the bar against a sheet of drywall
supported by the support tool.
[0036] FIGS. 6-9 show components of a construction panel support
system 50 in use to position and temporarily support multiple
construction panels P (shown as sheets of drywall), relative to
adjacent installation sites on a ceiling joist C. In general,
system 50 includes one or more construction panel positioning tools
10 (such as tool(s) 100, as shown in FIGS. 1-2, and/or tool(s) 200,
as shown in FIGS. 3-4, and so forth), and one or more construction
panel support tools 40 (such as tool(s) 300, as shown in FIG. 5).
The structural components (i.e., joists W, C, and the drywall
sheets P) and tools are not necessarily shown to scale, but rather
are presented somewhat schematically for the sake of
illustration.
[0037] In FIG. 6, a positioning tool 10 according to the first
illustrated embodiment 100 is shown to be secured to a wall joist W
such that the upper surface 24 of the support platform 16 is spaced
from an adjacent ceiling joist C by a distance sufficient to
accommodate a construction panel P. Construction panel P is shown
with its forward edge placed on the upper surface 20 of the ramp
section 18, and is guided up the ramp section in the direction
shown by the arrow, such as if a worker holding the opposite edge
pushes the panel along the ramp section. Although only one
positioning tool 10 is shown in FIG. 6, two or more positioning
tools may be deployed in parallel along a wall frame, such as to
provide greater stability and support through the use of multiple,
parallel ramp sections.
[0038] In FIG. 7, the forward edge of the construction panel P has
been guided to the upper surface of the support platform, and is
supported in position to be installed. The middle section of the
construction panel P may then be pivoted upward and away from the
ramp section, as shown by the arrow, such as by a worker lifting
the opposite edge toward the ceiling.
[0039] In FIG. 8, a support tool 40 according to the illustrated
embodiment 300 is shown to be movably suspended from ceiling joist
C, and is moved into place so that the support member 44 engages
the bottom surface of the construction panel P. In general, the
support tool 40 engages the ceiling joist from which it is
suspended loosely enough to be moved easily along the length
thereof, for example so that a worker supporting the panel with one
hand against the ceiling joists may reach back with the other hand
to pull or otherwise slide the tool 40 into place. Again, although
only one support tool 40 is shown in FIG. 8, two or more support
tools may be deployed, for example to provide multiple points of
support. The construction panel P is now in place relative to the
installation site, and may be installed according to conventional
methods, after which the positioning tool(s) 10 may be removed and
the support tool(s) 40 may be moved from a supporting position.
[0040] In FIG. 9, a positioning tool 10 according to the second
illustrative embodiment 200 is shown to be secured to ceiling joist
C through construction panel P. Again, more than one positioning
tool may be used, such as to provide multiple, parallel ramp
sections. Also, the support tool has been moved away from the wall
sufficiently to allow a second construction panel P to be raised
and supported into position relative to an installation site
adjacent to the installed construction panel. Continuing in this
manner, a solo worker Say sequentially install multiple
construction panels to the entire ceiling frame.
[0041] Several configurational variations may be made to the
illustrative embodiments within the scope of the invention. For
example, although the positioning tools 10 are shown to be of rigid
construction, other embodiments may employ hinged, adjustable
connections, such as a selectively pivotable coupling between the
stabilizing member and the ramp member, so that a single unit relay
be employed for installation sites that are adjacent to walls as
well as those that are not adjacent to walls, for example by moving
the stabilizing member between vertical and horizontal
orientations. Further, although the range of angles formed between
the ramp section and a horizontal plane in the prototype
embodiments is about 35 to 45 degrees, an angle anywhere in the
range of about 20 to 60 degrees, or beyond, would have utility in
certain applications. Moreover, the inclusion of an
adjustable-angle coupling may provide a positioning tool capable of
providing such a range. Optionally, the positioning tool components
forming the ramp member and/or stabilizing member may be of
adjustable length, such as by employing a telescoping
configuration, so that the positioning tool may be used in a
greater number of applications. For example, ceiling heights in
many installations may vary quite a bit, and a positioning tool
with a ramp member of adjustable length may allow the vertical
distance that a construction panel must be lifted in order to place
the forward edge onto a ramp section to be kept minimal. Further,
some embodiments of the positioning tools may include additional
components, such as braces or supporting struts, as might suitable
for a heavier-duty application, and/or multiple iterations of a
particular component, such as parallel ramp members, multiple
stabilizing members, and so forth; whereas others may include fewer
components, such as indicated above, in which some embodiments of a
positioning tool does not include a support brace. In some
positioning tools, the stabilizing member may instead or
additionally couple to the ramp section, and/or may be configured
to engage one or more structural components of a building structure
in a different manner than as shown. Moreover, the support tools 40
may include a suspension frame that remains in place on a ceiling
joist, but may instead (or additionally) feature a slidable and/or
pivotable support arm that is movable relative to the suspension
frame.
[0042] Although the present invention has been shown and described
with reference to the foregoing operational principles and
illustrated examples and embodiments, it will be apparent to those
skilled in the art that various changes in form and detail may be
made without departing from the spirit and scope of the invention.
The present invention is intended to embrace all such alternatives,
modifications and variances that fall within the scope of the
appended claims.
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