Abstract:
A multi-purpose spacer provides working surfaces for properly spacing studs, joists, rafters, and decking. The spacer (also referred to herein as a “tool” or “jig”) includes an adjustable spacer for balusters used in staircase railings, deck railings, and the like. The spacer may be constructed of a light metal, preferably aluminum, or suitably rugged plastic, and may also include a removable, padded handle to ease transport and use. Embodiments of the invention provide a spacing tool that is (for all practical purposes and in accordance with typical tolerances in the framing carpentry industry) completely temperature- and humidity-immune as well as waterproof.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 12/198,502, filed Aug. 26, 2008, the entire contents of which is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    Carpenters on the job typically perform many tasks over and over, such as framing wall studs, floor joists, and roof joists (also known as rafters), installing decking, building balustrades and staircases, and installing trim. In order to save time, jigs or other fixtures or tools are used to make hold work pieces (e.g., studs or decking) in place with a regular, repeatable spacing relative to other pieces. While a number of jigs and the like are commercially available, existing jigs suffer from a number of shortcomings. First, because they are designed for a single repetitive task, they are usually not very versatile or able to do other tasks. Second, as the nature of the work typically calls for large spacers (e.g., 16 inches on center for studs, 18 or 24 inches on center for joists or rafters), the jigs themselves tend to be somewhat larger than a toolbox. When a carpenter needs three or four jigs, his transport and storage space can rapidly fill up. 
         [0003]    What is needed is a single, multi-purpose spacer jig capable of providing the major carpenter&#39;s spacing functions, namely stud, joist/rafter, and decking installation spacing in a single, compact tool. 
       SUMMARY 
       [0004]    A multi-purpose spacer provides working surfaces for properly spacing studs, joists, rafters, and decking. The spacer (also referred to herein as a “tool” or “jig”) includes an adjustable spacer for balusters used in staircase railings, deck railings, and the like. The spacer may be constructed of a light metal, preferably aluminum, or suitably rugged plastic, and may also include a removable, padded handle to ease transport and use. 
         [0005]    Embodiments of the invention provide a spacing tool that is (for all practical purposes and in accordance with typical tolerances in the framing carpentry industry) completely temperature- and humidity-immune as well as waterproof. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]    The foregoing and other objects, features and advantages of the invention will be apparent from the following description of particular embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. 
           [0007]      FIG. 1  is an isometric view of a multifunction spacer tool according to one embodiment of the present invention. 
           [0008]      FIG. 2  is a front view of a multifunction spacer tool according to one embodiment of the present invention. 
           [0009]      FIG. 3  is a back view of a multifunction spacer tool according to one embodiment of the present invention. 
           [0010]      FIG. 4  is a right end view of a multifunction spacer tool according to one embodiment of the present invention. 
           [0011]      FIG. 5  is a left end view of a multifunction spacer tool according to one embodiment of the present invention. 
           [0012]      FIG. 6  is a top view of a multifunction spacer tool according to one embodiment of the present invention. 
           [0013]      FIG. 7  is a bottom view of a multifunction spacer tool according to one embodiment of the present invention. 
           [0014]      FIG. 8  is an isometric view the baluster spacer fingers according to one embodiment of the present invention. 
           [0015]      FIGS. 9A-9C  illustrate an alternative embodiment of baluster spacer fingers adapted to be retracted for storage. 
           [0016]      FIG. 10  illustrates alternate embodiment for the baluster spacer function of this multi-purpose tool. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Embodiments of the present apparatus are directed to a device for spacing and holding materials in place while they are being fastened or otherwise installed. The apparatus may be used with wood, metal, or composite framing and other building materials. The tool is intended for general carpentry, and may be configured especially for use in construction of decking, stairs, framing, and so forth. It will be understood that while the following description emphasizes English units for dimensions and construction standards common in the United States (e.g., inches, feet, pounds, etc.), the devices described herein may be suitably adapted to use in other geographic regions that apply partially or completely different units and standards, such as the metric system (e.g., meters, millimeters, grams, etc.). 
         [0018]      FIG. 1  shows an isometric view of an embodiment of tool  100  with a padded handle  102  attached at a handle cutout  103  to a floorboard spacer  110 . On the opposite side of tool  100 , shown in position for use, is a stud spacer  120 , which consists of a center chord  122  and two end caps  126 A and  126 B. In an embodiment, the distance from the outer side  128 A of one end cap  126 A to the outer side  128 B of the other end cap  126 B is 14½ inches, the standard inside spacing between studs placed 16 inches on center using typical 1½ thick dimensional lumber (e.g., the nominal 2×4 or 2×6 commonly used in the construction trade). 
         [0019]    The floorboard spacer  110  may include a pair of spacing surfaces formed by opposing sides of the single, planar part  110  that extends upward at a right angle from a center line of the center deck  130 . This pair of spacing surfaces may be separated by a distance selected to space, for example, floorboards, decking or the like, or any other building components that might be consistently spaced a relatively small distance apart. This may be, for example, one sixteenth of an inch, one eighth of an inch, one quarter of an inch, one half of an inch, or any other thickness suitable for spacing floorboards and the like. 
         [0020]    The end caps  126 A and  126 B (also described herein with reference to the spacing surfaces formed by opposing, exterior sides of the end caps) may serve multiple purposes. In general, the end caps  126  present a pair of opposing, substantially parallel and substantially planar surfaces that extend from a bottom side of the center deck  130  and at a right angle thereto. This pair of spacing surfaces may be separated by a distance selected to space studs or the like, or more generally at a desired distance for any spacing function. In the position shown, the end caps  126  may also allow the tool  100  to stand on its own, so that it may be used to lay out and assemble wall sections laid flat on the floor or ground. The flat surface prevents tool  100  from being twisted out of square to the stud material during lay-up, ensuring accurate spacing. 
         [0021]    The center deck  130  may be a substantially planar piece of material(s) measuring 16 inches long by 4 inches wide. While numerous dimensions may be employed, a sixteen inch length also provides a convenient, physical reference for actual center-to-center distances studs, which may assist in marking centers or the like. In another exemplary embodiment, the center deck  130  may have any length greater than the spacing surfaces of the end caps  126  useful for spacing in a construction environment. More generally, the length of the center deck  130  and the distance between the spacing surfaces of the end caps  126  may be selected to equal any commonly repeated spacing distance useful in construction. 
         [0022]    Baluster spacer fingers  150  may be provided, also referred to herein simply as “fingers” (one of two being shown in the figure) as an adjustable spacer. When provided, the fingers  150  may allow repeatable positioning of balusters with an adjustable inter-baluster spacing, discussed further below. In general, the adjustable spacer formed by the fingers  150  and related hardware may provide for continuous spacing, or discrete spacing at intervals such as one sixteenth of an inch, one eighth of an inch, one quarter of an inch, and so forth. In one embodiment, as described below, the spacer may include adjustable fingers supported by a mechanical locking system that secures the fingers at one sixteenth inch intervals. The adjustable spacer may, for example, provide for spacing at discrete or continuous intervals ranging from, e.g., three-quarters of an inch to four inches, or over any other suitable range. It will be understood that a variety of techniques are known in the art for moving and locking two or more surfaces, any of which may be adapted to use as an adjustable baluster spacer, or more generally an adjustable spacer, as described herein. 
         [0023]      FIG. 2  is a front view of the tool  100 , showing a padded handle  102  removably attached to the floorboard spacer  110 . The handle  102  may be attached with small bolts, such as industry standard 1/4 inch×1¼ inch hex-head machine screws or similar fasteners (not shown). The handle  102  may also, or instead, attach with a friction fit or other engagement to the tool  100 . The handle  102  may be removable so that it may be attached to the stud spacer  120  at the cutout  220  and thereby allow the tool  100  to be inverted and used to space deck boards or other flooring material by inserting the floorboard spacer  110  between two pieces of floorboard, decking material, or the like. The thickness of the floorboard spacer  102  is selected so as to provide sufficient strength to tool  100  while not exceeding the typical floor or decking board-to-board spacing of 1/16 or ⅛ inch. 
         [0024]    In one exemplary embodiment, the handle  102  is made of soft rubber, although it may be made of wood or metal. However constructed, the handle  102  may provide a cushioned gripping surface. 
         [0025]    The floorboard spacer  110  may be attached to the center deck  130  through any of various means well known in the arts for attaching two plates, such as (but not limited to) welding, brazing, attachment via fasteners, or adhesives. Attached to the lower (in the view of  FIG. 2 ) surface of the center deck  130  are the center chord  122  and the end caps  126 A and  126 B, together forming the stud spacer  120 . The baluster spacer fingers  150  are shown in dashed line to illustrate that the depicted position (a “deployed” position), is movable, such as among various spacings, or between the deployed position and a stowed position in which the fingers  150  can be inserted into and contained within a perimeter of the center deck  130 . 
         [0026]      FIG. 3  is a reverse side view of the tool  100 . 
         [0027]      FIG. 4  is an end view, looking into the baluster spacer fingers  150 . In some embodiments, the center deck  130  includes a slot  410  or other opening in an end thereof in which the fingers  150  may be positioned at a user-set, variable spacing relative to each other. This feature is discussed in more detail below. In an alternate embodiment, no baluster spacer fingers  150  or center deck slot  410  is provided. 
         [0028]      FIG. 5  is an end view of the other end of tool  100 . 
         [0029]      FIG. 6  is a top view of tool  100 , looking down on the handle  102 , the floorboard spacer  110 , and the center deck  130 . The baluster spacer fingers  150 A and  150 B are clearly shown in this top view. The baluster spacer fingers  150  made be made of any hard, durable material either the same as or different than that of the body of the tool  100 . Additional detail of the operation of baluster spacer fingers  150  is discussed below with regard to  FIGS. 8 and 9 . 
         [0030]      FIG. 7  is a bottom view of the tool  100 , looking “up” at the stud spacer assembly  120  (i.e., at center chord  122  and end caps  126 A and  126 B). 
         [0031]      FIG. 8  shows an exemplary embodiment of the method of attachment of the baluster spacers  150  to the center deck  130 . In some embodiments, the baluster spacer fingers  150 A and  150 B are moveably located in the slot  410  in the center deck  130 . The fingers  150 A and  150 B may be secured, in some embodiments, by means of set screws (or similar fasteners)  810  inserted through a set screw slot  820  to engage threaded holes (not shown) in the fingers  150 . The set screws  810  may be long enough to protrude through the fingers  150  and to contact the surface  830  of the center deck  130  opposite the set screw slot  820  while simultaneously also protruding into the set screw slot  820 . In this way, the set screws  810  prevent the fingers  150  from falling out of the center deck slot  410 . Alternatively, the set screws  810  may be #8×⅛ inch Allen screws commonly used in the mechanical arts, although those skilled in the art will realize that many other set screws including non-Allen screws and screws of various sizes, lengths, threads, and so forth may be suitably adapted to use with the devices described herein. In some embodiments, at a desired length, the set screws  810  do not protrude into the set screw slot  820  when tightened into contact with the surface  830 . Accordingly, the invention is not limited to any particular type of set screw. 
         [0032]    In one exemplary embodiment, the baluster spacer fingers  150  are 2 inches long, ¾ inches wide, and ⅛ inch thick, although various sizes could be used in coordination with a corresponding depth and thickness of the center deck slot  410 . 
         [0033]      FIGS. 9A-9C  illustrate an exemplary embodiment of baluster spacer fingers  900  adapted to be retractable for storage within center deck slot  410 . From an extended position such as that shown in  FIG. 8 , fingers  900  may be rotated inward as shown by arrows  910  in  FIG. 9A . Note that, in this illustration, the center deck slot  410  is shown on the stud spacer side of the tool  100 . One of ordinary skill in the art will recognize that center deck slot  410  can be on either the stud-spacer side or the floorboard-spacer side of the tool without impacting the utility or function of the device. In this embodiment, the set screws  920 , whose length is equal to or slightly less than the thickness of the fingers  900 , are retracted into the fingers  900  so that the fingers  900  are able to slide out of the center deck slot  410 . 
         [0034]      FIG. 9B  shows the fingers  900  rotated parallel to the long axis of the center deck slot  410 , which is also parallel to the set screw slot  820 . The set screws  920  are still retracted (screwed) into the fingers  900 , which allows the fingers  900  to be fully inserted into the center deck slot  410 , as shown in  FIG. 9C . In this stowed position, set screws  920  are then screwed down, into, and partially through the fingers  900 , to contact the surface  830  (referring to  FIG. 8 ) of the center deck  130  to secure the fingers  900 . 
         [0035]    In a further alternate embodiment, the baluster spacer fingers  900  (or  150 , as shown in  FIGS. 1-8 ) may have formed on their outer edges thumb knurls or tabs  950 . The thumb knurls  950  may serve as gripping points for sliding the fingers to or from their stowed position ( FIG. 9C ). The thumb knurls  950  may be formed as an integral part of the fingers or may be applied or fastened to them later. 
         [0036]    In a still further embodiment, the projecting portion of the center deck  130  encompassing the center deck slot  410  may have marked on it upper and/or lower surfaces a measuring scale  960 , such as that exemplified in  FIG. 9B , for assistance in positioning the spacer fingers  900  equidistant from the centerline of the tool. Alternatively, any other measuring scale known to those in the art may be used, without limitation, to allow the craftsman to set the spacing distance between the fingers. The scale  960  may also be used in conjunction with detents machined or otherwise formed in the surface  830  of the center deck slot  410  so that the set screws  920  may be rapidly positioned at regular intervals, in one embodiment of 1/16th of an inch, across the width of the tool. 
         [0037]    In embodiments where the set screws  920  are Allen screws, an Allen (hexagonal or “hex”) wrench or “key” is needed to loosen and tighten them. This tool may, in some exemplary embodiments, be stowed in a hole drilled in the end of the handle  110  (referring to  FIG. 1 ). Such holes, commonly used in the art, are of a diameter slightly smaller than the widest dimension of the hex wrench and secure the wrench with friction. In a further alternate embodiment, the handle  110  may be attached to the tool  100  by bolts or screws that are tightened using the same size Allen key. This eliminates the need to use a separate the tool to remove the handle  102  and replace it on the other side of the tool at a cutout  220  (referring back to  FIG. 2 ) before using the floorboard spacer  110 . 
         [0038]    Other techniques for fixing two movable, slidable, rotatable, and/or removable fingers or other supports in a fixed-distance relationship are also known in the art, and may be suitably adapted to use in an adjustable baluster spacer as described herein. 
         [0039]      FIG. 10  illustrates another alternate embodiment for the baluster spacer function of this multi-purpose tool. Here, the tool  1000  utilizes stair step tongues  1010  and  1020  to provide fixed spacing in increments of 1/16th of an inch. In one exemplary embodiment, the tongue  1010  provides spacings from 2½ to 4 inches in 1/16th inch steps and the tongue  1020  provides spacings from 1 to 2½ inches in 1/16th inch steps. One of ordinary skill in the art will appreciate that tongue widths, increment sizes and combinations thereof may be varied to provide other amounts and varieties of spacing intervals without departing from the spirit of this invention. Also, the invention may be practiced with only one tongue or two tongues of the same configuration. Accordingly, the scope of the present invention is not to be limited by the step size or spacing intervals of the tongues. Other tongue shapes and step sizes may also usefully be employed. 
         [0040]    The multifunction spacer may be made of any material now known or discovered in the future, for example (but not by way of limitation, wood, metal, plastic, composite materials, or any combination thereof. Accordingly, fabrication of the present invention is not limited to any particular material, unless specifically stated otherwise in the present disclosure. In certain embodiments, the entire tool  100  may be formed of a single, integral piece of material that may be cast or otherwise molded. In other embodiments, the main body of the tool  100  may be integrally formed except for the adjustable baluster spacers. 
         [0041]    While particular embodiments of the present invention have been shown and described, it will be apparent to those skilled in the art that various changes and modifications in form and details may be made therein without departing from the spirit and scope of the invention as defined by the following claims, which are to be interpreted in the broadest sense allowable by law.