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RELATED INVENTIONS  
       [0001]    This application is a continuation-in-part of and claims priority to U.S. provisional patent application serial No. 60/293,383 entitled Beam Alignment and Bracing Apparatus and Apparatus for Making Same, which was filed on May 23, 2001. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. The Field of the Invention  
           [0003]    The invention relates to alignment tools and more specifically, to systems and methods of aligning beam systems. In particular, the invention is directed to aligning, spacing, and supporting truss and stud systems.  
           [0004]    2. The Relevant Art  
           [0005]    Trusses for building construction are generally fabricated off-site and then lifted into position upon framed walls. The trusses must be uniformly spaced and held in properly spaced vertical alignment while the roof decking is installed. Upon installation, the roof decking maintains the spatial alignment of the trusses.  
           [0006]    A common residential construction method by which a truss system is assembled begins with individual truss units being shipped to the construction site. At the construction site walls are formed, and generally include an upper beam which supports the trusses. The truss units are placed upon the supporting beams to span the distance between the walls. A plurality of truss units is placed in a row with a selected spacing between trusses. Typical spacings are 12, 16, and 24 inches. The trusses should be accurately spaced from each other to provide uniform strength.  
           [0007]    One difficulty with truss units is stabilizing and bracing the units after attachment to the supporting wall but before installation of the roof decking. Truss units have a height dimension that is much greater than their width dimension. Therefore, trusses are prone to tipping, and care must be taken to avoid a “domino” effect.  
           [0008]    Alignment and bracing tools have numerous applications in many fields, but are particularly important in construction applications such as truss installation. Many alignment tools are commonly available and come in many forms such as flexible tapes, and rigid poles.  
           [0009]    One type of alignment and spacing tool of the prior art comprises a plurality of tool segments each of which is designed to extend between a pair of adjacent truss units. Each tool segment is configured to engage a surface of the truss unit. Rivets are provided to connect each tool unit, and permit adjacent tool members to pivot about each other, which allows the segments to fold up much like a foldable measuring stick. Disengaging a tool such as this for reuse is possible, but at times difficult. Alternative systems perform in a manner consistent with their design, but are expensive and are not compact and easily transported.  
           [0010]    A need exists in the art for a spacing/bracing apparatus that is easy to use and that is simply and inexpensively manufactured. The present invention is directed to filling this previously unmet need.  
         OBJECTS AND BRIEF SUMMARY OF THE INVENTION  
         [0011]    The alignment guide of the present invention has been developed in response to the present state of the art, and in particular, in response to the problems and needs in the art that have not yet been fully solved by currently available alignment guides. Accordingly, it is an overall object of the present invention to provide an alignment guide that overcomes many or all of the above-discussed shortcomings in the art. A method of use of the alignment guide, as well as a method and apparatus for making the alignment guide are also provided.  
           [0012]    In one embodiment provided herein, the alignment guide comprises a top surface configured to adjoin a selected surface of a beam member and a plurality of alignment tabs protruding outward from the surface. The tabs are preferably spaced so that the beam is received against the top surface between the tabs. The tabs may be pointed to catch and hold the beam within two or more tabs.  
           [0013]    The alignment tabs preferably protrude outward and may protrude in a direction substantially perpendicular to the top surface. Two or more of the alignment tabs may be configured to form a slot for receiving the beam member. In one embodiment, the alignment guide is formed from a lightweight rail of rolled U-channel metal. The U-channel is configured with a plurality of flanges disposed along the edges of the U-channel. The alignment tabs are stamped in pairs on the flanges with the distance between each tab corresponding to the selected thickness of the beam member.  
           [0014]    One advantage of the alignment guide of the present invention is that the profile of the top portion of the alignment guide is receivable into the bottom portion such that a plurality of alignment guides may be stacked. Holes adjacent the alignment tabs allow the alignment tabs from a lower stacked alignment guide to protrude through the holes.  
           [0015]    The alignment guide may be fabricated from a commonly available prefabricated member. A plurality of apertures may be formed in the alignment guide, through which a fastener can pass for fastening the alignment guide to the beam member. Under a preferred embodiment of the present invention, the alignment tabs are configured to be disengageable for reuse.  
           [0016]    In order to use the alignment guide of the present invention, a first beam is secured manually in place. The first beam and an unsecured second beam are then received into the respective slots formed by the alignment tabs. Fasteners such as nails may be passed through openings in the alignment guide to temporarily fasten the engagement guide to the beams. Once the beams are secured in place, the alignment guide may be disengaged for reuse.  
           [0017]    The alignment guide of the present invention may be configured to align a truss system wherein the truss system comprises at least a first and a second truss unit. Alternatively, the alignment guide may be configured to align a stud system wherein the stud system comprises at least a first and a second stud unit.  
           [0018]    Under a preferred embodiment of the present invention, an apparatus for fabricating an alignment guide comprises a press, a head frame adjoining the press, and a plurality of cutter prongs vertically disposed along the head frame. Also provided are a plurality of push rods disposed along the head frame, a plurality of guide assemblies disposed at first and second ends of the head frame, an anvil disposed parallel to and below the head frame, and a plurality of immobile guide posts disposed at each end of the anvil.  
           [0019]    In one embodiment, the press comprises a hydraulic press. The press may be a commonly available hydraulic log splitter. The anvil may comprise an I-beam. The position and separation of the plurality of cutter prongs is preferably adjustable. The plurality of cutter prongs may comprise pairs of cutter prongs with a separation configured to receive a beam. The separation of pairs of cutter prongs is in one embodiment approximately 1⅝ inches. The separation between pairs of cutter prongs is approximately 24 inches. The push rods are preferably configured to be immobile and are used to remove the alignment guide from the head frame.  
           [0020]    The method of fabricating an alignment guide comprises providing a press, placing a commonly available prefabricated member in the press, and punching a plurality of alignment tabs into the prefabricated member within the press.  
           [0021]    These and other objects, features, and advantages of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0022]    In order that the manner in which the advantages and objects of the invention are obtained will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:  
         [0023]    [0023]FIG. 1 is a top view of an alignment guide of the present invention.  
         [0024]    [0024]FIG. 2 a  is a side view of the alignment guide of FIG. 1.  
         [0025]    [0025]FIG. 2 b  is an end view of the alignment guide of FIG. 1.  
         [0026]    [0026]FIG. 3 is a perspective view of the alignment guide of FIG. 1.  
         [0027]    [0027]FIG. 4 is a perspective view of implementation of the alignment guide of FIG. 1.  
         [0028]    [0028]FIG. 5 is a schematic flow chart diagram illustrating one embodiment of a method for aligning a beam system of the present invention.  
         [0029]    [0029]FIG. 6 is a perspective view of a fabricating press of the present invention.  
         [0030]    [0030]FIG. 7 is an end view of an anvil of the fabricating press of FIG. 6.  
         [0031]    [0031]FIG. 8 is a schematic flow chart diagram illustrating one embodiment of a method for fabricating an alignment guide of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0032]    [0032]FIG. 1 shows a top view of the alignment guide  100  of the present invention. The alignment guide  100  is quite simple, and its simplicity is one of it advantages. The alignment guide  100  comprises a spacer rail  102  consisting of lengths of rolled metal channel, sometimes referred to as U-channel but more properly referred to as “hat” channel. Under a preferred embodiment of the present invention, the spacer rail  102  has a length of approximately 10 feet. The spacer rail  102  is a lightweight metal strip rolled into a U-shape cross section to provide a moment of inertia against bending. Thus, the channel is preferably rigid against bending.  
         [0033]    The spacer rail  102  has a plurality of flanges  104  disposed along the edges (at the tips of the “U”). In one embodiment, triangular-shaped tabs  106  are punched out of the flanges  104  and bent outward. The tabs  106  may be pointed to catch the beams between two or more tabs  106 . The tabs  106  are preferably stamped in pairs, with the distance between each tab in a pair corresponding to the thickness of a beam member (in one embodiment, about 1½ to 1¾ inches for a truss made from 2×6 lumber). Alternatively, the distance between pairs of tabs  106  may be configured to receive a beam member of any dimension.  
         [0034]    The distance between adjacent tab  106  pairs corresponds to the desired distance between trusses. Typically this distance is approximately 12, 16, or 24 inches. Thus, the alignment guide  100  of the present invention is used to align trusses by receiving a truss between the tabs  106  in each pair of tabs (one tab on each side of the truss, in very close adjacency thereto). In one embodiment, a pre-drilled aperture  108  is supplied between the tabs  106  of each pair, so that a single (e.g. double-headed) nail can be driven through the spacer rail  10 - and into the truss. This temporarily secures the channel to the truss.  
         [0035]    Apertures  108  provide for optimal placing and easy driving of nails. Alternatively, nails can be driven directly through the flanges  104 . Under a preferred embodiment of the present invention, the alignment guide  100  typically is ten feet long, about 2⅞ inches wide, and ⅞ inches high. The punched tabs  104  are preferably spaced to receive 2-inch lumber, such as “two by fours” or “two by sixes,” from which trusses typically are constructed. In one embodiment, a distance of approximately 24 inches separates the tab pairs  107 . Alternatively, the distance between tab pairs  107  may correspond to the selected center-to-center separation distance of the trusses. Once the truss is placed between the tabs, a duplex nail may be driven, either through the nail hole  108  or directly through the flange  104  between the tab pairs  107 , and into the truss.  
         [0036]    Referring jointly now to FIGS. 2 a ,  2   b , and  3 , shown therein is a side elevation, an end sectional elevation, and an enlarged perspective view of a short section  200  of the alignment guide  100  of FIG. 1. The punched tabs  106  are typically spaced to receive 210 inch lumber, such as “two by fours” or “two by sixes,” from which trusses are commonly constructed.  
         [0037]    Referring now to FIG. 4, shown therein is one example of a manner of implementing the alignment guide  100  of the present invention. The alignment guide  100  is configured to receive the top surface of a truss  402  and set the spacing between a plurality of roof trusses  402 . Of course, this is only one of the many applications of the present invention. The alignment guide  100  may be cut to any length using common tools such as tin snips. Therefore, the alignment guide  100  may be modified to span any distance less than the length of the alignment guide  100 . The flange edges  104  may also be cut, and the top plane or spine of the alignment guide  100  bent, so that the bottom chord  404  of the truss  402  may be aligned. This is required when the trusses  402  are assembled in a non-standard manner.  
         [0038]    [0038]FIG. 5 shows a schematic block diagram illustrating a method  500  of using the alignment guide  100  of the present invention. The method  500  starts and an alignment guide  100  is provided  504 . The alignment guide  100  is preferably configured as described above. In so doing, alignment tabs  106  are formed in the alignment guide  100 . One method of fabricating the alignment guide  100  and tabs  106  will be discussed with greater detail below with reference to FIG. 8. Typically, the first beam is supported  508  on the building structure by conventional fastening means. Thereafter the alignment guide  100  receives the first beam  510 .  
         [0039]    After the first beam is supported  508 , and the separation distance between beams is determined, the alignment guide  100  receives the next beam  512 . If there are additional beams  514 , then the alignment guide  100  receives  512  the beams. As a plurality of trusses is fitted between tabs and nailed, the alignment guide  100  holds the trusses in spaced relation while they are permanently attached to the framing. Alternatively, the beams are secured  516 , and the alignment guide  100  is removed  518 . Thus, the alignment guide  100  may be removed for reuse or left permanently in place according to the preference of the user.  
         [0040]    [0040]FIG. 6 is a perspective view of an apparatus  600  for the fabrication of an alignment guide such as the alignment guide  100 . A head frame assembly  602  is connected to a driven “ram” (not shown). The head frame assembly  602  is a long beam mounting with appropriately located pairs of vertically disposed cutter prongs  604 . The head frame assembly  602  is pressed downward to force the cutting prongs  604  through the flanges  104  of the alignment guide  100 . Disposed parallel to and below the head frame assembly  602  is an anvil  606  having a corresponding length upon which the spacer rail  102  is supported during the tab punching step. The apparatus  600  may be driven by a commonly available hydraulic press such as log splitter.  
         [0041]    Also seen in FIG. 6 is a plurality of horizontal tubular frames  608 , connected to the anvil  606 , with rods  610  depending downward therefrom. The rods  610  serve as immobile push rods that push the alignment guide  100  off the head frame assembly  602  after the punching step has occurred. Once the cutter prongs  604  have perforated the flanges of the rail  102 , the press section is raised from the anvil  606 . Ordinarily, the cutter prongs  604  remain frictionally engaged in the holes perforated in the flanges  104 . However, once the alignment guide  100  reaches a predetermined height, the alignment guide  100  comes in contact with the bottom ends of the rods  610 ; continued upward movement of the head frame assembly  602 , and contact with the immobile rods  610 , causes the perforated alignment guide  100  to be pushed off the cutting prongs  604 .  
         [0042]    [0042]FIG. 7 shows an end view of a preferred embodiment of the anvil  606 . The body of the anvil  606  may be fashioned from a length of I-beam  702 . Under a preferred embodiment of the present invention, the I-beam is approximately 6 inches high and 4 inches wide. Disposed centrally upon the top surface of the upper flange of the I-beam  702 , axially along its length, is a supporting block  704  having a stacked configuration. In one embodiment, the supporting block  704  is made from a first  706  and a second  708  bar stock member. The first bar stock member  706  preferably has dimensions of ⅜ inch by 1½ inch. The first bar stock  706  may be welded to the I-beam  702 .  
         [0043]    In one embodiment, the second bar stock  708  has dimensions of ⅜ inch by 1¼. The second bar stock  708  is preferably welded parallel to and upon the first bar stock  706 . The second bar stock  708  forms the portion of the supporting block  704  that is disposable within the interior recess of the spacer rail  102 . The second bar stock  708  supports the spacer rail  102  and prevents a collapse of the spacer rail  102 . The wider first bar stock  706  offers support to the laterally extending flanges  104 . During operation of the head frame assembly  602 , the spacer rail  102  is placed concave side down upon the supporting block  704  and held while the cutter prongs  604  are pressed through the flanges  104  of the spacer rail  102 .  
         [0044]    [0044]FIG. 8 shows a schematic block diagram illustrating a method  800  of fabricating the alignment guide  100  of the present invention. The method  800  starts and a press is provided  804 . A length of spacer rail  102  is placed  806  upon the anvil  606 . The head frame assembly  602  is lowered and the alignment tabs  106  are punched  808 . The alignment guide  100  is then removed  810  and the method ends  812 .  
         [0045]    The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

Summary:
Disclosed is an alignment guide and a method for beam aligning and bracing. The alignment guide of the present invention comprises alignment tabs punched into a commonly available spacing rail. The alignment guide is lightweight and economical. A plurality of alignment guides may be stacked for ease of transportation. The method comprises supporting a first beam and receiving the first beam and a plurality of beams to be spaced into the space formed by the alignment tabs. The beams are supported and spaced by the alignment guide until they have been fastened into place. Also disclosed is an apparatus for the manufacture of the alignment guide with which alignment tabs are economically punched into a commonly available prefabricated spacing rail.