Abstract:
A tool used to install pickets on the railing of a deck. The railing of a deck comprises two horizontal support members and a plurality of pickets. The device has a rearward surface that is adapted to engage a picket or support post. There are two indicating locations on the tool that correspond to the correct location of a second picket to be installed. Indicating marks are made on a horizontal support member and the second picket is placed in between the indicating marks and attached thereto.

Description:
This application claim the benefit of provisional application No. 60/146,220, filed Jul. 28, 1999. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates to a method and apparatus to assist in building decks, and more particularly to the installation of vertical members that must be evenly spaced and substantially parallel to each other. The present invention is particularly advantageous for the installation of pickets that are a component of a railing for a deck. 
     BACKGROUND 
     Wooden decks are often provided for homes and they are generally level and somewhat elevated from the ground. Surrounding the deck is a railing to prevent a person from accidentally falling off a deck. The railing generally comprises an upper rail support, a lower rail support and pickets. The pickets are positioned vertically between the upper rail and the lower rail. There must be a minimal horizontal distance between adjacent vertical surfaces of the pickets in order to comply with local building codes; however, the pickets should not any closer to each other than necessary. 
     The proper positioning of these pickets is a somewhat time consuming task that must be accomplished reliably. For example if one of the pickets is out of alignment then the pickets that are placed in a position parallel to the misaligned picket repeat the mistake along the length of the railing. 
     SUMMARY OF THE INVENTION 
     The present invention provides a tool that is simple in design, inexpensive to manufacture and easy to use for assisting in building decks. The tool is used to create indicating marks on a horizontal beam. These marks are then used to position vertical members between the header and footer horizontal beams. 
     The tool comprises a frame member and a flange. In a preferred embodiment, the frame member is trapezoidal in shape and has a front end and a rear end. The flange is positioned at the rear end of the frame member and in a plane substantially perpendicular to the frame member. The frame member further comprises a lower portion and an upper portion. A base edge is located at the lower portion of the frame member. The base edge is perpendicular to the plane which the flange is located in. A first and second indicator locations are located on the base edge that are each positioned at a predetermined location from the rearward surface of the flange. The perpendicular distance from the first location to the rearward surface of the flange is denoted as ‘a’. The perpendicular distance from the second indicator location to the rearward surface of the flange is denoted as ‘b’. 
     In a preferred embodiment, the tool further comprises and open portion located in the central area of the frame. The central area defines a third indicator that is positioned at a perpendicular distance ‘a’ from the base edge. The upper portion of the frame defines an upper edge that is parallel to the base edge. The perpendicular distance from the upper edge to the base edge is ‘b’. Further in the open portion a level can be located. This level can indicate whether the base edge is vertical or the flange is horizontal. 
     The environment the tool is designed to operate is in deck construction. A deck railing is used to help prevent people and movable objects from falling off the deck. Pickets must be placed in the deck railing at a specific distance to comply with building codes and to maintain a safe deck. When constructing a railing there is an upper rail support and a lower rail support. The upper rail support comprises two upper support beams and a horizontal cap. The lower rail support comprises two lower support members. The pickets are horizontally spaced between the two upper support beams and the two lower support beams. 
     During construction of the railing, the pickets are positioned perpendicular to one of the upper support beams and one of the lower support beams and then are nailed to each beam. To horizontally space the next picket, the tool is positioned so the rearward surface of the flange is in contact with a fixed picket and the base edge is in contact with one of the beams. The worker then creates two marks on the beam so the location of these marks correspond to the location of the two indicators on the base edge. These two marks are used to position the next picket. 
     An alternative method of marking the next picket is to hang the tool by the forward surface of the flange so the tool&#39;s base edge is in contact with the previously positioned picket. Then the worker can make a mark on the upper beam at the third indicator position and another mark along the upper edge. Then a new picket can be positioned in-between these two marks. 
     The leveling device can be used to ensure the pickets are vertical or the railing is horizontal. Also, the width of the frame member can be used to separate the deck planks. 
     BACKGROUND ART 
     The usual method of positioning pickets has been to use a tape measure determine the horizontal spacing between the pickets. A search of the prior art Patent literature has disclosed a number of patents directed toward the positioning of various members in wood structures or the like, and these are the following: 
     In U.S. Pat. No. 4,237,614 is an adjustable locator for furring strips. The present invention has no such similar construction and has a different functionality. The adjustable locator has a flange with an inturned portion and a channel shaped member to engage furring strips. This embodiment is not designed to create indicating marks on a horizontal beam but rather its design is for grasping actual firing strips. Further the invention in the &#39;614 patent requires calibration and an assembly of several pieces. 
     In U.S. Pat. No. 3,201,874 is a self-spacing stud guide that has two jaws to engage studs. This invention is also designed to hold studs and not simply mark the locations where they are to be located. The embodiment in the &#39;874 requires two instruments to function; each holding two studs in position. 
     In U.S. Pat. No. 4,958,814 is an interval locator similar to the &#39;873 patent. This invention also operates on a somewhat different principal where the interval locator holds the building components in place and then they are fixed in place. Further this device lacks functional elements of the present invention. 
     In U.S. Pat. No. 5,031,886 shows a framing aid that comprises a template where studs are positioned in a template and nailed to top and bottom plates. The template is single piece member that that is molded to hold studs and a top or bottom plate. This patent utilizes a completely different technique of assembling vertical members. 
     Finally the U.S. Pat. No. 5,490,334 show a tool that is used to position a stud to a footer or header. The tool utilizes a cradle that snugly fits a loose stud. The tool then positions the stud a set distance from a fixed stud and the loose stud is then nailed to the header or footer. This invention is used to install a loose stud to a fixed stud and is not designed to make measurement marks on the header or footer. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 a  shows an isometric view of the tool taken from an upper and forward perspective. 
     FIG. 1 b  is a view similar to FIG. 1 a  but taken from a rearward and lower perspective; 
     FIG. 2 is a side view of the tool; 
     FIG. 3 a  is a front view of the tool; 
     FIG. 3 b  is a top view of the tool; 
     FIG. 4 is an isometric view of the tool in one operating position in an environment which in this embodiment is the construction of a wood a deck railing; 
     FIG. 5 is a close up isometric view of the tool in its operating position as in FIG. 4, where the tool is located on the lower support beam of the deck railing; 
     FIG. 6 is another isometric view of the tool where the tool is positioned in a different manner than in FIG. 4 or  5 ; 
     FIG. 7 is an isometric view of the tool where the tool is positioned in another operating position on the upper support beam of the railing; 
     FIG. 8 is a side view of the tool located on the upper support beam as in FIG. 7; 
     FIG. 9 is a front cross sectional view of the upper portion of a railing with the tool located thereon as in FIGS. 7 and 8; 
     FIG. 10 is a cross sectional view of a completed upper railing; 
     FIG. 11 is an oblique view of the tool being used to space deck planks; 
     FIG. 12 is another side view of the tool similar to FIG.  2 . This figure shows sample dimensions of the tool; 
     FIG. 13 shows the environment where the tool is used; 
     FIGS. 14-16 shows alternative functional shapes of the frame member; 
     FIG. 17 shows a second embodiment of the present invention where the level portion is repositioned in the base portion of the apparatus. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Throughout this description reference is made to top and bottom, front and rear. The device of the present invention can, and will in practice, be in numerous positions and orientations. These orientation terms, such as top and bottom, are obviously used for aiding the description and are not meant to limit the invention to any specific orientation. 
     As seen in FIG. 1, the tool  20  comprises a unitary structure  21  which comprises a frame member  22  and the flange  24 . For the sake of clarity and accuracy of description, a coordinate system  26  is defined where there is the vertical axis  28 , the lengthwise or longitudinal axis  30  and the transverse axis  32 . The transverse direction is defined to as traveling in the direction indicated as  32  or  32 ′. Although in actual use the tool  20  can be easily rotated, the vertical axis  28  will still denote a direction extending from origin point  36  to the upper portion  38  regardless of the tool&#39;s orientation (e.g. where the tool is in the position shown in FIG. 10 the vertical axis runs from right to left). 
     The frame member  22  comprises an upper portion  38 , a lower portion  40 , a forward portion  42  and a rear portion  44 . The frame member  22  is positioned substantially to occupy an alignment plane defined by the vertical and longitudinal axis, and in the preferred form the frame  22  is a planar member. The frame member has a width  23  dimension in the transverse direction. Located in the upper portion  38  is an upper edge surface  39  that at least partially lies in an upper surface plane  41  that is defined by the longitudinal axis  30  and the transverse axis  32 . 
     As best seen in FIG. 1 b , located at the lower portion  40  of the frame member  22  is a base portion  46 . The base portion  46  comprises a base edge  48 , a base edge surface  50 , a first indicator  52  and a second indicator  54 . The base edge surface  50  at least partially lies in the base surface plane  51 , which is defined by the longitudinal and transverse axis. The first and second indicators  52  and  54  can be a notch that is formed from the base edge surface  50 , the indicator can be any indicating means (indentation or line in the frame surface  45 , etc.) that can be used to accurately measure a distance from the flange  24 . 
     As seen in FIGS. 1 a  and  1   b  located in the rear portion  44  of the frame  22  is the flange  24 . The flange  24  is planar and substantially lies in the plane that is defined by the vertical and transverse axes ( 28  and  31  in FIG. 1 a ). The flange  24  has an upper portion  56  and a lower portion  58 . Further, the flange  24  has a forward surface portion  60  and a rear surface portion  62 . The rear surface portion  62  of flange  24  has a rear contact surface  64  (see FIG. 1 b ), and located at the forward surface portion  60  is a forward contact surface  66  (see FIG. 1 a ). The rear contact surface  64  substantially lies in a rear contact plane  65  that is defined by the vertical axis  28  and transverse axis  32 . Likewise, the forward contact surface  66  substantially lies in a forward contact plane  67  that also is defined by the vertical axis  28  and transverse axis  32 . Located in the lower portion  58  of the flange  24  is an abutment surface  68  which is in the same plane as base edge surface  50 . 
     FIG. 3 b  shows a top view of the tool  20  where the flange  23  of the rear portion  44  has a first flange portion  61  and a second flange portion  63 . The first flange portion  61  is connected to the frame member  22  at a first juncture area  71  and the second flange portion  63  is connected to the frame member  22  by a second juncture area  73 . 
     It is desirable for the frame member  22  to have an open middle area  70  defined by an inner perimeter edge  72  and located in the central portion  74  of the frame member  22 . In the rear portion  44  there is a vertical inner edge  76  that is part of the inner perimeter edge that that runs parallel to the vertical axis  28 . A third indicator  78  is positioned on this inner edge  76 . The third indicator  78  is similar to the first and second indicators  52  and  54  and is used to measure a distance from the base surface plane  51 . The indicator can be a notch, line or other device in order to mark a surface adjacent to the frame member  22 . 
     As seen in FIG. 2, the distance from the rear contact plane  65  and the first indicator  52  is indicated as ‘a’. The distance from the rear contact plane  65  and the second indicator  54  is denoted as ‘b’. The distance ‘a’ is the desired distance between two pickets. The distance ‘b’ represents the distance of the desired space between two pickets plus the horizontal width of a picket. 
     In a similar manner, the distance ‘a′’ is the perpendicular distance from the base surface plane  51  and the third indicator  78 . 
     The distance ‘b′’ is the perpendicular distance between upper surface plane  41  and the base surface plane  51 . The distance ‘a′’ is the same as distance ‘a’ which represents the distance gap between two pickets. The distance ‘b′’ is the same as the distance ‘b’ which is the distance gap between two pickets plus the horizontal width of a picket. As will become apparent from the description later herein, this enables the functions of the present invention to be accomplished more easily. 
     One operating environment for the tool  20  is shown in FIGS. 4-10. In a first mode of operation as seen in FIGS. 4 and 5, there is a deck railing  79  in the process of being built. At this stage in construction vertical posts are in place and the deck railing  79  comprises an upper support beam  80 , a lower support beam  82  and some pickets  84 . The beams  80  and  82  are attached to vertical posts. The pickets  84  are vertically positioned between the beams  80  and  82 . The pickets  84  must be horizontally spaced from each other so that the distance gap ‘a p ’ is distance that complies with building regulations or maintains a safe deck (e.g. two-five inches). 
     When the tool is positioned as seen in FIGS. 4 and 5, the rear contact surface  64  of the flange  24  is in contact with the forward picket surface  85  of picket  84 . The flange  24  extends in the transverse direction so the rear contact surface  64  is in contact with the forward picket surface  85  while the base edge surface  50  of frame member  22  is in contact with the upper surface  83  of the lower support beam  82 . Next the worker will make indicating marks  86  and  88  on the lower support beam  82 . These marks can be created by a scratch, pencil mark or any method of marking a location on the lower support beam  82 . The indicating mark  86  is positioned to correspond to the distance ‘a p ’ and the indicating mark  88  is positioned to correspond to the distance ‘b p ’. The tool can now be removed and a new picket can be placed in-between the indicating marks  86  and  88 . 
     With reference to FIG. 6, the worker can rotate the tool  20  ninety degrees clockwise about the transverse axis from the position in FIG. 4 and 5 and further rotate the tool one-hundred and eighty degrees about the vertical axis to position the tool  20  as shown in FIG.  6 . This positioning of the tool  20  is useful for the worker to ensure that the picket is perpendicular to the lower support beam  82  and ensures that that the picket is vertical (assuming that the lower support beam is already level). The flange  24  enables the tool to be positioned on the top surface  83  of the lower rail  82 , with the base edge surface  50  being in contact with the picket  84 . Alternatively the worker can use the level  55  of the frame member  22  to ensure the picket is vertical. 
     To position the upper ends of the pickets  84 , the procedure that is illustrated in FIGS. 7-10 is utilized. While one of the many benefits of this present invention is that it can be used very conveniently to position both the upper and lower ends of the pickets  84 , it should be recognized that the method shown in FIGS. 7-10 can be used independently or in conjunction with the aforementioned method shown in FIGS. 4-6. The method consists of hanging the tool  20  from the upper support beam  80 . This hanging is accomplished by placing the forward contact surface  66  of the flange  24  in contact with the upper beam surface  90  of the support beam  80 , so that the base edge surface  50  of frame member  22  is in contact with the forward picket surface  85  of picket  84 . Next the worker creates indicating marks  92  and  94 . These marks can be created in a similar manner to the marks  86  and  88 . The indicating mark  92  represents a location that is a distance ‘a p ’ from the forward picket surface  85 . The indicating mark  94  represents a location that is a distance ‘b p ’ from the forward picket surface  85 . After the worker creates these marks he can remove the tool  20  and position the upper end of the picket being installed in between the marks  92  and  94  on the upper support beam  80  and secure the new picket  84  thereon. The securing process can include nailing gluing or any effective means of securing the picket to the upper support beam  80 . This process could be used in a similar manner to install the picket  84  in the lower support beam  82 . Having the upper edge surface  39  a perpendicular distance ‘b p ’ from the base edge surface  51  is particularly advantageous for creating the indicating mark  94 . The worker can easily position a pencil or other marking object along the upper edge surface  39  of the frame member  22  to create the indicating mark  94 . 
     FIG. 8 shows a cross-sectional view with the tool  20  with the tool  20  in the operating position of FIG.  7 . The final assembly of the upper rail support  96  requires attaching another upper support beam  80  to the pickets  84  and then attaching a horizontal cap  98  above the upper support beams  80 . The horizontal cap  98  can be a 2×6 piece of wood and the support beams  82  and  80  can be 1×6&#39;s. 
     The procedures shown in FIGS. 4-6 and in FIGS. 7-10 can advantageously be used together in positioning each picket where indicating marks  86  and  88  can be made on the lower support beam  82 , and the indicating marks  92  and  94  being made on the upper support beam  80 . A new picket can be positioned between these sets of marks and nailed to the support beams. 
     A further method of installing pickets is where the rear contact plane  65  of the tool  20  could be aligned with the indicating mark  88  so the mark lies in the contact plane  65 . Then worker could create two more marks  86  and  88  on the lower support beam  82  at the position of the first and second indicators  52  and  54  of tool  20 . This process can be repeated along the length of the lower support beam  82  prior to installing the pickets. A similar method can be accomplished on the where the base surface plane  51  would be aligned with indicating mark  94  on the upper support beam  80  so the indicating mark  94  lies in the plane of the base surface plane  51 . Then the worker could create a first and second marks  92  and  94  on the upper support beam  80  that correspond to the location of the third indicator  78  and the upper surface plane  41  of the tool  20 . The worker would then use the second mark to align the base surface plane of the tool  20  to repeat the measuring and marking process. This method of hanging the tool  20  could similarly be used on the lower support beam as well. 
     Another use of the tool  20  is illustrated in FIG.  11 . The width  23  of the frame member  22  is desirable equal to the spacing distance between deck planks  100 . These planks  100  are attached to a support beam  102  and must be evenly positioned from each other a relatively small distance (e.g. ⅛ of an inch). A new plank  104  is positioned next to an attached plank  100 . Next the forward portion  42  of tool  20  is inserted in-between the planks  100  and  104 . Finally the new plank  104  is nailed or otherwise attached to the support beam  102 . 
     FIG. 12 shows some possible dimensions of the tool  20  and it further shows a few more points of interest. The tool  20  has outer corners  110 ,  112 ,  114  and  116  and there are inner corners  118 ,  120 ,  122  and  124 . Inner edge  72  further comprises front inner edge  130  and lower inner edge  132 . Front edge  126  is positioned in the front portion of the tool  20 . 
     It should be noted that the open middle area  70  allows the worker to more easily grip the tool  20  thereby making any portion of the inner edge  72  a handle to come in contact with the workers fingers or palm. 
     The frame member could be constructed in a variety of shapes although the frame member is particularly advantageous in a trapezoidal shape for purposes of having the forward point  134  to be used to separate deck planks  102 . Other functional designs are shown in FIG.  14 . The flange  24  is shown extending in positive and negative transverse directions from the frame member  22 . The flange could be constructed to only extend in the positive transverse direction or in the negative transverse direction. Although this could only allow the tool to hang from on side of the frame  22 . 
     FIG. 17 shows a second embodiment of the present invention where the apparatus  140  as a first level  142  positioned in the rearward portion. Further, a second level  144  is positioned in an orthogonal relationship to first level  142 . The first and second levels  142  and  144  had a width that is proximate to the width of the frame portion  146 . This allows the front open surface of the frame  146  to be flush against a flat surface. Of course additional levels at desirable angles (e.g. thirty, forty-five, sixty degrees) could be employed. 
     While the invention is susceptible of various modifications and alternative forms, specific embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It s should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but, on the contrary, the intention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as expressed in the appended claims.