Device and method for joining and supporting pieces of sheet material

A method and device for joining two pieces of sheet material using a unique joinder device are disclosed. The joinder device comprises first and second flange portions and a rib disposed between and interconnecting the flange portions. The rib extends in a direction perpendicular to a plane of the flange portions so that, when the joinder device is employed to join two pieces of sheet material, each of the flange portions lies flat against an interior side of the pieces of sheet material and the rib is disposed between the adjacent, abutting ends of the pieces of sheet material. Fasteners are driven from an exterior side of, and through, the pieces of sheet material so that distal ends of the fasteners are anchored in holes which are preformed in the first and second flange portions.

TECHNICAL FIELD 
The present invention relates to a device and method for joining pieces of 
sheet material (for example, sections of wall board, drywall, plywood or 
the like). 
BACKGROUND ART 
In the field of construction in general, and in the construction and repair 
of walls and ceilings in particular, a common problem relates to the 
joining together of two adjacent sections of wallboard, drywall, plywood 
or the like into a contiguous, non-broken wall or ceiling. If a contiguous 
non-broken wall is not obtained, the fact that work has been done will not 
be hidden from the viewer, and the customer will not be satisfied. 
Another problem in this area of construction results from the fact that, 
when two or more sections of sheet material are joined together, the point 
of joinder of the sheets of material often does not fall on or coincide 
with a supporting stud or beam. As a result, proper support for the sheet 
material is not obtained. This problem is especially prevalent when 
repairing holes in existing sheet material with other pieces of sheet 
material cut to the size of the hole being repaired. That is to say, quite 
often in such cases, the perimeter of the hole being repaired does not 
correspond with a supporting stud or beam, so that there is no support 
provided for the sheet material which is to be joined to the existing 
sheet material along the perimeter of the hole being repaired. 
Thus, there is a need in the construction business for a method and device 
for joining pieces of sheet material in such a manner as to provide a 
contiguous non-broken wall so that the fact that work has been done in 
that area can be easily concealed from the viewer. There is also a need in 
the field of construction for a method and device for joining pieces of 
sheet material in such a manner as to provide support for the resulting 
combined structure, even in the absence of a supporting beam or stud at 
the location of the joinder. 
DISCLOSURE OF INVENTION 
The present invention generally relates to a device and method for joining 
two pieces of sheet material (such as wall board, drywall, plywood or the 
like). 
More particularly, the invention relates to a method and device for joining 
two pieces of sheet material wherein the device comprises first and second 
flange portions and a rib disposed between and interconnected with the 
first and second flange portions, the rib extending in a direction 
perpendicular to a plane of the first and second flange portions. In 
accordance with the invention, the device further comprises a plurality of 
fasteners (such as rivets, drywall screws, or the like), one for each of 
the two pieces of sheet material being joined, for interconnecting the two 
pieces of sheet material by passing from an exterior side of the sheet 
material, through the sheet material preferably to a hole or holes 
preformed in the first and second flange portions. 
Preferably, the length of the rib is less than the thickness of the sheet 
material, and the screws are fastened so as to become seated flush with 
the interior surface of the sheet material, resulting in a structure in 
which the joinder between the adjacent pieces of sheet material can be 
easily hidden. 
Therefore, it is an object of the present invention to provide a device and 
method for joining two pieces of sheet material. 
It is an additional object of the present invention to provide a device for 
joining two pieces of sheet material having first and second flange 
portions and a rib disposed between and interconnecting those portions. 
It is an additional object of the present invention to provide a method and 
device for joining two pieces of sheet material, wherein a plurality of 
fasteners, one for each of the pieces of sheet material, interconnects the 
pieces of sheet material to the first and second flange portions, 
respectively. 
It is an additional object of the present invention to provide a device and 
method for joining two pieces of sheet material, wherein the dimensions of 
the rib are such that the point of joinder between the two pieces of sheet 
material can be easily hidden from view once the job is completed. 
It is an additional object of the present invention to provide a device and 
method for joining two pieces of sheet material, wherein the plurality of 
fasteners is positioned and dimensioned so that the fact that the pieces 
of sheet material have been joined together can be easily hidden from the 
viewer. 
The above and other objects, and the nature of the invention, will be more 
clearly understood by reference to the following detailed description, the 
accompanying drawings, and the appended claims.

BEST MODE FOR CARRYING OUT THE INVENTION 
The invention will now be described in more detail with reference to the 
various figures of the drawings. 
FIG. 1 is a plan view of the device of the present invention, while FIG. 2 
is a side-cross-sectional view of the device of FIG. 1. As seen therein, 
the joining device (or joining bee) 10 basically comprises flange portions 
12 and 14 interconnected by a rib portion 16. As best seen in FIG. 1, in a 
preferred embodiment of the invention, perforations or holes 18 for 
receiving the ends of fasteners (to be discussed below) are pre-formed in 
the flange portions 12 and 14. 
The device and method for joining two pieces of sheet material will now be 
described in more detail with reference to FIGS. 3 and 4 of the drawings, 
which are side, cross-sectional views of the device of the present 
invention utilized to join two pieces of sheet material. 
Referring to FIGS. 3 and 4, when a person desires to join pieces 20 and 22 
of sheet material, the device 10 is positioned so that flange portions 12 
and 14 lie flat against an interior side of sheet material pieces 20 and 
22, respectively, and so that the rib portion 16 of the device 10 is 
sandwiched between abutting ends of the sheet material pieces 20 and 22. 
In order to permanently connect sheet material pieces 20 and 22, fasteners 
24 and 26 are driven through pieces 20 and 22, respectively, so that the 
distal ends of the fasteners 24 and 26 become screwed into holes 18 (see 
FIG. 1) formed in flange portions 12 and 14 respectively of the device 10. 
As indicated previously, any number of holes or no holes 18 may be formed 
in the flange portions 12 and 14 of the device 10, but preferably several 
groups of clustered holes 18 are formed therein, and this facilitates the 
use and connection of the device 10 to the sheet material pieces 20 and 22 
by a person of less skill, that is, a person who does not work in the 
construction business on a routine basis. In addition, as would be obvious 
to a person of ordinary skill in the art, sheet material pieces 20 and 22 
can have pre-formed holes or perforations contained in a portion adjacent 
to their abutting ends so as to facilitate the insertion of the fasteners 
24 and 26; on the other hand, since sheet material pieces 20 and 22 can be 
wallboard or drywall, or other easily penetrated material, it is not 
absolutely necessary that pre-formed holes or perforations be provided in 
the pieces 20 and 22. 
Referring to FIG. 4, once the device 10 and the pieces 20 and 22 are 
permanently interconnected via fasteners 24 and 26, the pieces 20 and 22 
are ready for the finishing process. In that regard, it should be noted 
that, in accordance with the present invention, the ribbed portion 16 is 
preferably of a length less than the thickness of the pieces 20 and 22 
being joined, so that, when the device 10 is interconnected with the 
pieces 20 and 22, no part of the rib portion 16 protrudes from the gap 
between the pieces 20 and 22; that is, a flush relationship is maintained 
between the exterior sides of the pieces 20 and 22. As a result of this 
feature of the present invention, the finishing process is relatively 
simplified. 
During the finishing process, finishing tape 28 is applied to the exterior 
sides of the pieces 20 and 22 so as to cover the gap between the end or 
abutting portions of the pieces 20 and 22, and a finishing compound 30 is 
applied over the finishing tape 28, thereby establishing a smooth surface 
which conceals the fact that joinder of the pieces 20 and 22 by use of the 
device 10 has taken place. That is to say, an unbroken appearance in the 
finished wall structure is provided by virtue of employment of the device 
of the present invention. 
It should be noted that the device 10 is preferably sufficiently rigid to 
substitute for traditional wooden studs normally found in building 
structures, thereby enabling one to employ the device 10 at a wall 
location in which no stud is provided, or to employ the device 10 as a 
substitute for a conventional wooden stud at an intermediate location of 
the wall. 
In addition, as previously mentioned, the device 10 of the present 
invention can be employed in connection with repairing or patching a 
damaged wall section. In that regard, the device 10 is, in a preferred 
embodiment, able to be cut to a size necessary to repair or patch such a 
damaged wall section, even where the damaged wall section is smaller than 
a standard for 8'.times.8' wall board section. 
Finally, the device 10 of the present invention can be used as a sealing 
joist for reinforcement of ceiling panels against sag, especially where a 
suspended ceiling is in place. In such an application, numerous devices 10 
are installed at predetermined intervals along the perimeter of ceiling 
panels, thereby providing the needed reinforcement for suspended ceiling 
panels. 
The device 10 can be formed of any suitable material and in any suitable 
size. However, preferably, the device 10 is made of galvanized steel, and 
is manufactured in lengths of approximately 8 feet or 12 feet, in 
correspondence to the lengths of the edges of the sheet material pieces to 
be joined. 
While preferred forms and arrangements have been shown in illustrating the 
invention, it is to be understood the various changes and modifications 
can be made without departing from the spirit and scope of this 
disclosure.