Abstract:
The invention comprises novel apparatuses and methods for positioning and/or for determining the locations of one structural member such as a stud, rafter or joist on another structural member such as a beam during construction.

Description:
FIELD OF THE INVENTION 
     The field of the invention is building construction-related apparatuses and methods. 
     BACKGROUND OF THE INVENTION 
     This invention relates to apparatuses for simplifying the framing of buildings and to methods for making and using the apparatuses. 
     It is known to use pre-marked tapes or templates for locating each of a series of structural members used in construction such as studs, rafters or joists on a connecting structural member such as a top plate or bottom plate in the case of studs being nailed to a top or bottom plate to form a panel. One type of prior art pre-marked tape or template has a definite starting point, a definite end point and a predetermined length of 192 inches. It is used to measure that single distance. One side of this type of prior art pre-marked tape or template is self-adhesive and is stuck on the connecting structural member such as a top plate or bottom plate to which the series of structural members is being fastened. The tapes or templates include markings indicating the center location for each of the series of structural members. An example of this type of tape is disclosed in U.S. Pat. No. 6,494,014. 
     The prior art pre-marked tapes or templates have several disadvantages, such as for example: (1) under some circumstances they come loose before the structural members such as studs, rafters or joists have been properly fastened in place; (2) they are unable to locate structural members such as studs, rafters or joists over a distance longer than 192 inches without using multiple end to end tapes or templates or reusing the same tape or template by placing its starting point at the last marking and extending it a second time; (3) they are not as convenient nor as desirable to use to locate the studs or rafters or joists; and (4) some tapes or templates have so many markings on them that they are confusing in actual use. 
     It is known to dispense strapping tape in continuous lengths on spools and in boxes that can be used as dispensers. Some prior art tapes are adhesive and some dispensers of strapping tape have cutting blades attached to them for ease in cutting the tape. It is also known to mount steel strapping tape in rolls on dollies for convenience. 
     However, the prior art does not suggest the manner of using or usefulness of such applicators in the positioning or in determining the location of structural members during construction of buildings. 
     It is known to angularly position structural members with respect to each other by drawing a line on one of the structural members using a squaring tool and then aligning the edge of the other structural member along the line. This method has the disadvantage of being time-consuming. 
     SUMMARY OF THE INVENTION 
     Accordingly, it is an object of the invention to provide a novel apparatus and method for positioning and/or for determining the locations of one structural member such as a stud, rafter or joist on another structural member such as a beam during construction. 
     It is a further object of the invention to provide a novel method of making a tool for locating the positions of structural members. 
     It is a still further object of the invention to provide a novel apparatus and method for angularly positioning a first structural member with a second structural member to which it is to be fastened. 
     It is a still further object of the invention to provide a novel method and apparatus for reducing cumulative errors in positioning structural members. 
     It is a still further object of the invention to provide a novel construction technique and novel tools useful in using the novel technique. 
     It is a still further object of the invention to provide a novel method and novel apparatuses for rapidly fastening structural members in place in construction projects. 
     In accordance with the above and further objects of the invention, there are provided a novel angular-positioning tool and a novel structural member-locating tool, which in the preferred embodiment, is a locating tape or template. The angular positioning tool and the structural member-locating tool can be used together or separately in construction to fasten structural members together at the proper angles and at the proper locations with respect to each other. The tape or template has markings on each side indicating the proper location for fastening structural members such as studs to other structural members such as the top and bottom plate of framework panels. While the markings may be different distances apart, in the preferred embodiment, one side of the tape or template has markings spaced 16 inches from each other and the other side has markings spaced 12 and/or 24 inches from each other. The novel angular-positioning tool has at least a first positioning surface for positioning a first structural member and a second positioning surface for positioning a second structural member at a predetermined angle to the first structural member. 
     In one embodiment, the angular-positioning tool has two orientating portions that may be or are fixed in angular position with respect to each other. A first of the two orientating portions positions a stud, rafter or joist and the second of the two orientating portions positions the structural member to which the stud, rafter or joist is to be fastened. This requires at least one orientating surface on each of the first and second orientating portions against which the structural members can be positioned. 
     In one embodiment, the first orientating portion holds a stud, rafter or joist within a “U”-shaped member having either a flat side for orientating the stud, rafter or joist or flat orientating flanges extending from the flat side fitting against the sides of the stud, rafter or joist or both. In this embodiment, the second orientating portion is also a “U”-shaped member having either a flat side fitting against the sides of the cross member or orientating flanges extending from a flat side fitting against the sides of the cross member or both. 
     In the preferred embodiment, a locating opening is provided in the angular positioning tool for viewing marks on the tape or template and for fasteners for fastening structural members together such as by nailing the structural members together. The flanges are positioned parallel to each other and orthogonal to a connecting member of the “U”-shaped member to provide guide surfaces for angularly positioning the structural members such as studs, rafters or joists with their matching members. The open end of each of the “U”-shaped members is opposite to the locating opening so that the construction worker can insert the angular-positioning tool from the same side as the locating tape or template. 
     Advantageously, the angular-positioning tool: (1) has wide enough members to extend between the surface of a construction workers hand and the structural members being stapled; and (2) is of sufficient size and made of strong enough material to shield the hand from nails. With this construction, the angular positioning tool also serves as a safety device to avoid accidental hitting of a worker by nails. 
     The structural member-locating tool is particularly useful in fastening structural members such as studs, rafters and joists across the full length or width of a building. For example, in fastening joists, the use of a tape across the full length of the building avoids the prior art practice of climbing a ladder at several locations to mark the location of the joists along a beam. Instead, the tape or template is stretched across the length and left in place to locate the joists when they are fastened in place. For convenience in laying the tape or template, the tape or template is continuous and may be packaged in spools or boxes used as dispensers and may be mounted to a dolly or cart and dispensed from the dolly or cart. Sections of the continuous tape or template may be cut to size and used rather than requiring a full tape of fixed dimensions which requires that the tape or template be attached with its starting point at a first predetermined location and its end at a second predetermined location a fixed distance from the first predetermined location. The continuous tape or template should be made of a material having an elastic limit greater than 25 psi. Its modulus of elasticity should be more than 100,000 psi. 
     From the above description, it can be understood that the apparatus and tools of this invention have several advantages, such as: (1) the tape or template is reusable under some circumstances but is inexpensive enough to be disposable and left in place when used; (2) the tape or template is easy to use and clearly marked; (3) the tape or template may be securely fastened by staples so as not to come loose in use; (4) the angular positioning tool provides a convenient method for positioning a structural member at an angle with respect to a second structural member; (5) the structural-member locating tool may be used to position structural members over the entire length or any portion of the length of a building to avoid cumulative errors and high set up time for marking beams; and (6) some embodiments of structural-member locating tools may be conveniently positioned and fastened in place from spools or dolly-mounted dispensers or from boxes. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above noted and other features of the invention will be better understood from the following detailed description when considered in conjunction with the following drawings, in which: 
         FIG. 1  is a fragmentary perspective view of a section of frame for the side of a building with a construction tool positioned for use in accordance with an embodiment of the invention; 
         FIG. 2  is a fragmentary plan view of one side of the marking tape or template in accordance with an embodiment of the invention; 
         FIG. 3  is a fragmentary plan view of the opposite side of the tape or template of  FIG. 2 ; 
         FIG. 4  is a perspective view of an angular-positioning tool in accordance with an embodiment of the invention; 
         FIG. 5  is another perspective view of the angular-positioning tool of  FIG. 4  taken from another angle; 
         FIG. 6  is a fragmentary enlarged perspective view of a marking tape or template positioned to measure the location of structural members such as studs, rafters or joists against a bottom plate of a section of building frame; 
         FIG. 7  is a simplified, fragmentary perspective view of the manner in which the construction tools of this invention may be used by a construction worker; 
         FIG. 8  is a simplified, perspective, fragmentary view of a portion of a panel, with the lower portion of three studs, a structural member-locating tool and an angular positioning tool in position to aid in the locating and positioning of one of the studs; 
         FIG. 9  is a simplified elevational view of a panel illustrating a first stage in another manner of using the structural member-locating tool in accordance with an embodiment of the invention; 
         FIG. 10  is a simplified elevational view of a panel illustrating a second stage in the manner of using the structural member-locating tool in accordance with an embodiment of  FIG. 10 ; 
         FIG. 11  is a plan view of a residential foundation illustrating the different methods in which the structural member-locating tool may be utilized in a timesaving manner to position floor joists; 
         FIG. 12  is a plan view of wall panels that bear on floor rafters and trusses illustrating one manner of using the structural-member locating tool; and 
         FIG. 13  is a flow diagram of a process for using the structural member-locating tool and angular-positioning tool in accordance with an embodiment of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In  FIG. 1 , there is shown a simplified perspective view of the frame work  10  of a section of a building having a top plate  12 , a bottom plate  14 , and a plurality of structural members such as studs, rafters or joists  16 A- 16 J. A structural member-locating tool  18 B is shown positioned on the bottom plate  14  for locating the bottom of the structural members such as studs, rafters or joists  16 A- 16 J on the bottom plate  14 . In the preferred embodiment, the structural member-locating tool is a tape or template  18 A and  18 B. A similar or identical tape or template  18 A may be used to position the top of the structural members on the top plate  12  as well. 
     As shown in  FIG. 1 , a marking  20 A, hereinafter referred to as structural member-locating indicia, indicating the center of the studs for all studs in a panel except a corner stud such as  16 A in  FIG. 1 , is placed at the outer end of the cross member (corner of building) as shown at  60  in  FIG. 1 . The section  60  in  FIG. 1 , hereinafter referred to as a structural member-locating tool end portion, is one half the width of the structural member, which is three quarters inch in the case of a stud such as  16 A in  FIG. 1 . However, in the case of other structural members such as joists or rafters, the distance will be different. In such cases the position locating tool may have additional markings so as to accommodate other size structural members and the proper end portion. 
     In this specification, the words “locating indicia” shall mean spaced apart markings or structural features indicating locations at which structural support members are attached to structural cross members. Similarly, in this specification the words “structural cross member or cross member” shall mean a structural member to which one or more other structural members, hereinafter referred to as structural support members, are to be attached at predetermined locations on the structural cross member or at predetermined distances from each other. For example, a top plate or a bottom plate of a panel in a frame of a house is a structural cross member because studs are attached to it at predetermined distances from each other. The words “structural support member” shall mean a structural member connected to a cross member to make a portion of a frame for a building or similar structure. For example, studs, rafters and joists are considered structural support members in this specification. 
     In  FIG. 2 , there is shown a fragmentary plan view of a first side of the tape or template  18  having a plurality of locating indicia or center points  20 A- 20 C indicating on one side of the tape or template the number of inches between locating indicia and on the other side the initials O.C. indicating that it is a center to center measurement. At the corner of a structure, the center point marking is placed at the outer edge of the first stud  16 A as shown in  FIG. 1  at the reference numeral  20 A rather than on center. The remaining structural members such as studs, rafters or joists in that panel are located with their center line being aligned with the center mark of the tape or template. The outer edge of the end stud is located on the center mark to allow space for other construction materials such as insulation or sheeting or the like. The distance is approximately one half the width of the structural support member. For example, in the case of studs, it is three quarters of an inch because studs are one and one-half inches in width. With this arrangement, the first two structural support members are closer to each other by one-half of their width than the other support members. When the insulation and other construction materials are added, the distance from a corner to the second support member is substantially the same as the center to center distances of support members other than the first and second support members. 
     In  FIG. 3 , there is shown a plan view of the other side of the tape or template  18  marked for other distances apart. In the embodiment of  FIG. 3 , it is marked for certain joists and rafters which are either 12 or 24 inches apart on center. To provide such marking or locating indicia without cluttering up the tape or template, each locating indicia is marked on one side with 12 and every other one is also marked with 24 to indicate the 12 inch and 24 inch markings Similarly opposite the marks of 12 or 24 are O.C. for on center. 
     In  FIGS. 4 and 5 , there are shown two different perspective views of an angular positioning tool  22  generally shaped as a “T” or an inverted “T.” In each of these views, one of the orthogonal sections is a stem member  26  and the other is a cross member  24 , with the stem member  26  intersecting the cross member  24  near its midpoint. Each of the two orthogonal sections  24  and  26  is “U”-shaped with a base plate and right and left side plates extending from the opposite edges of the base plate and being parallel to each other and perpendicular to the base plate. The side plates are spaced a distance apart to accommodate the structural member such as a stud. 
     Similarly, the cross member  24  includes right and left positioning members  34  and  36 . Each of the positioning members  34  and  36  includes a base plate such as  40  and  42  respectively for receiving one side of the crossing structural member such as a top plate in the case of a stud, and corresponding orthogonal members  44  and  46  positioned orthogonal to the base members  40  and  42  respectively. The orthogonal members  44  and  46  are at right angles to the respective base members  40  and  42  and are mounted with their edges spaced apart the same distance as between side members  30  and  32 , which is the width of a stud in the case of positioning structural members such as studs, rafters or joists with respect to upper or lower plates. 
     While any number of positioning surfaces may be used from two positioning surfaces with a first surface extending in one direction to provide a first positioning surface and a second surface extending in a direction and at an angle to the first surface to any larger number of surfaces, two sets of positioning surfaces are provided at right angles to each other in the preferred embodiment. One set includes three surfaces forming a “U” that holds a first structural member and a second set of three positioning surfaces that holds a second structural member at the selected angle to the first structural member. Additionally, one or more handles or openings for convenience in gripping the angular positioning tool may be provided. 
     While a specific configuration of orthogonal surfaces are shown in the embodiments of  FIGS. 4-5  for positioning structural members orthogonal to each other, there are many alternative configurations which could be used. Generally, the configurations must at least have one flat surface which is either permanently affixed or which can be affixed in use at a predetermined angle to another positioning surface. Preferably, at least one of those surfaces will have a second positioning surface orthogonal to it to position two sides of at least one of the structural members. 
     The angular-positioning tool  22  includes a window or opening  48  (shown in  FIG. 4 ) exposing one side of the cross-member such as the top plate to enable convenient viewing of the center mark of the tape or template. The window  48  also provides a convenient space for fastening such as by toe nailing with a staple or hammering a nail to the cross-structural members. 
     In  FIG. 6 , there is shown a fragmentary perspective view of a frame work section having a bottom plate  14 , and three structural members such as studs, rafters or joists  16 A- 16 C showing a manner in which the tape or template  18 B is used to position the bottom of the structural members such as studs, rafters or joists  16 A- 16 C at  16  inch centers with the end stud  16 A being 15¼ inches from the center mark of the stud  16 B as described above. 
     In  FIG. 7 , there is shown a simplified fragmentary elevational view of a panel  62  having a top plate  64 , a bottom plate  66 , and a plurality of studs  68 A- 68 J forming the panel. In preparing the panel, the structural member-locating-tools  18 A and  18 B are laid across the top plate  64  and the bottom plate  66  repeatedly. The locating indicia is aligned with the end of the cross member such as  64  with a portion of the structural member-locating tool extending beyond it. In the case of a stud, this end portion is three-quarters of an inch to allow for siding or other material. The structural member locating tools  18 A and  18 B are stretched over the cross members and the studs nailed by a workman such as shown at  70  in place at the top and bottom to form a panel. If the panel is prepared off site, staples may be removed at one end such as the end  72  and moved to a diagonal position such as  74  on the top plate  64 . Similarly, the top tape  18 A may be unstapled at  74  and moved to the corner  72  to have diagonal tapes holding the panel in shape for stacking and then removing. This has an advantage over the prior art method of nailing 2×4 braces because it is difficult to stack the panels for convenient moving with 2×4 braces in place. Un-stapling and moving the tapes is quick and efficient and because the tapes are thinner, the panels may be stacked after that and moved to the site for use in the building. 
     In  FIG. 8 , there is shown a simplified, perspective, fragmentary view of a portion of the panel  62  having the bottom plate  66  with the lower portion of three studs  68 B,  68 C and  68 D. As shown in this view, the angular-positioning tool  22  positioned to grip the stud  68 C and the bottom plate  66  and overlying the structural member-locating tool  18 B, with the window  48  being positioned to show a center marking  20 . With this arrangement, the angular positioning tool  22  may be located in such a manner to hold the stud  68 C conveniently over a center point. The window  48  is large enough to permit nailing of the stud in place at that location for accurate angular locating and longitudinal locating of the studs. 
     In  FIG. 9 , there is shown a simplified side view of a plurality of structural members such as studs, rafters or joists  68 A- 68 J, one of which is warped shown at  68 F. The tape or template  18  may be connected across these structural members such as studs, rafters or joists starting with an end stud and the warped stud may be positioned on center by forcing it into position using the tape or template. As shown in this view, the stud  68 F is warped so that where it crosses the structural member-locating tool  18  at the center of the panel, it will be spaced a distance from the center mark shown at  20 . Because of the existence of the center mark, the stud may be pulled over so that its center line is under the locating indicia and fastened in place to any cross member or any member fixed in place such as siding or plaster board or even a separate cross brace. 
     The warped stud may be positioned for example by a drywaller and when properly positioned to remove the warp fastened such as by gluing to the drywall. While a specific example of a warped stud has been given, there are many other such inconsistencies and other structural members which may be improperly positioned in the initial framing or other initial work. The use of the tape or template enables many of these to be properly positioned and fastened in place in the correct position. Similarly, the tape or template  18  may be positioned such as on the floor for the benefit of drywallers or finishers so they may locate the center line of structural members such as studs, rafters or joists for their use. 
     In  FIG. 10 , there is shown an enlarged elevational view illustrating the use of the structural member-locating tool  18  as shown in less detail in  FIG. 9 . In  FIG. 10 , the stud  68 F is shown between the studs  68 E and  68 G as shown in less detail in  FIG. 9  except the stud  68 F has been moved closer to the indicating indicia  20 E. In the use of the structural member-locating tool  18  illustrated by  FIGS. 9 and 10 , the stud will be forced completely into position by moving it to the right until the center line of the stud  68 E is lined up with the locating indicia  20 E and then fastened in place such as by a cross brace or by nailing it to drywall or sheeting or any other structural member that will be located in the same place to hold the stud in place. In this manner, other construction workers such as someone installing siding will have less difficulty in locating the stud to which the other material such as siding or drywall or the like is to be fastened. 
     The structural member-locating tool  18  may also be utilized for positioning other structural members after the framing has been done. For example, when siding is being applied, the location of the structural members such as studs, rafters or joists for fastening the siding, can be quickly and easily located by stretching the tape or template outside of the siding in a position aligned with the positioning of the tape or template when the structural members such as studs, rafters or joists were fastened. This will give the center on center positions for fastening the siding or other structural members in place. 
     In  FIG. 11 , there is shown a plan view of a residential foundation  80  illustrating the different methods in which the structural member-locating tool  18  may be utilized in a timesaving manner to position floor joists such as the floor joist  82 . In such an arrangement, one end of the structural member-locating tool  18  may be fastened at a convenient location at the end of the building and extended a full length to the opposite side of the building. In this specification, the words “full locating length” shall mean the total length over which structural support members are positioned under circumstances in which their positions are related such as by code regulations specifying the distance apart of the structural members. Thus the full positioning length may be the distance from one end of a building to the other end including any corners or the like included in the frame so that it may be longer than the width or length of the building. For example as shown in  FIG. 11 , one cross member  86  has a plurality of orthogonal cross members such as shown  84 A- 84 D to which floor joists may be fastened. The structural member-locating tool  18  may be fastened at any of the points  84 A- 84 D and extend across the orthogonal cross member such as illustrated at  88 B to the opposite end of the building as indicated at  88 B in  FIG. 11 . This arrangement may conveniently mark spaced apart locations for fastening the joists as shown at  82 . 
     Similarly, other sections of the structural member-locating tool  18  may be fastened at the ends  84 A,  84 C and  84 D and stretched straight across to the opposite end of the building. Each of these structural member-locating tools  18  has locating indicia aligned with the locating indicia on the member  88 B to provide aligned locations for fastening the floor joists. This is particularly convenient when the foundation such as that shown in  FIG. 11  consists of multiple corners extending in one direction to the other in providing accurate fastening locations such as shown at  90 A and  90 B since the tools may be moved from any location at the side of a building to the opposite side or to any other intermediate point that is convenient for the construction workers. With this arrangement, the structural member-locating tool  18  is continuously stretched from one end to another or to any intermediate point between the ends with no interruption. This use of the structural member locating tools  18  is particularly time saving in case of a foundation since the construction worker may fasten it at one end of the building and move to the second end and fasten it without moving up and down ladders every few feet. 
     In  FIG. 12 , there is shown a plan view of a building floor with floor rafters and trusses such as shown at  92 A- 92 C. In this application, the structural member-locating tool  18  is fastened at a point such as  94  and stretched across a structural member extending to the opposite side of the building such as shown at  96  or to some convenient intermediate member when desired. Thus, locating points may be found with the tape at any time. Similarly, a structural member-locating tool  18  may be fastened at other points such as the point  98  and stretched across a structural member to a corresponding point  100  to give another locating point for the fastening of the rafter or trusses, such as  92 A- 92 C. 
     In  FIG. 13 , there is shown a flow diagram of a process  102  for using the structural member-locating tool  18  including the step  104  of positioning the structural member locating tool with a locating indicia at the end of a structural cross member, the step  106  of stretching the structural member locating tool a full length along the two structural cross members to which the two ends of the structural support member are to be attached, the step  108  of placing an angular positioning tool on the first structural support member and on the cross members to hold the structural support member and cross member at the desired angle with respect to each other, the step  110  of fastening the first structural support member to the cross member with the outer side of the structural support member even with the side of the corner and end of tape or template extending past the side, the step  112  of placing the angular positioning tool on a second structural support member and on a cross member to hold the structural support member and cross member at the desired angle with respect to each other and with the center line of the second support member in alignment with the locating indicia, the step  114  fastening the support member to the cross member at both ends and the step  116  of repeat the locating and angular positioning and fastening steps until complete using the structural-support member for the full length. 
     From the above description, it can be understood that, the apparatus and tools of this invention have several advantages, such as: (1) the tape or template is reusable under some circumstances but is inexpensive enough to be disposable and left in place when used; (2) the tape or template is easy to use and clearly marked; (3) the tape or template may be securely fastened by staples so as not to come loose in use; (4) the angular positioning-tool provides a convenient method for positioning a structural member at an angle with respect to a second structural member; (5) the structural member-locating tool may be used to position structural members over the entire length or any portion of the length of a building to avoid cumulative errors and high set up time for marking beams; and (6) some embodiments of structural member-locating tools may be conveniently positioned and fastened in place from spools or dolly-mounted dispensers or from boxes. 
     Although a preferred embodiment of the invention has been described in particular detail, there are many modifications and variations in the invention that are not explicitly stated but known to be possible. Accordingly, within the scope of the appended claims, it is to be understood that the invention may be practiced other than as specifically described.