Patent Publication Number: US-2022234243-A1

Title: Lumber torque tools and methods

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to Provisional Patent Application No. 63/142,468 filed Jan. 27, 2021, the entire disclosure of which is hereby incorporated by reference and relied upon. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The invention relates generally to tools used to build wood structures, and more particularly to tools for straightening warped lumber including decking before fastening with screws or nails. This warpage in lumber is known as crook and twist. When joints are secured at one end, sometimes twist throws it out of alignment at an opposite end. Similarly, crook can disrupt alignment in the middle section of lumber. 
     SUMMARY OF THE INVENTION 
     Disclosed herein are carpentry tools and their methods of use that are designed to subdue warpage in lumber. 
     In one form, a lumber torque tool is utilized to straighten lumber. 
     In one form, the lumber torque tool requires only one hand for operation. 
     In one form, the lumber torque tool eliminates the need for assistance and saves time. 
     In one form, the lumber torque tool is sized for use with “2×” lumber such as 2×4&#39;s and 2×6&#39;s and 2×8&#39;s and 2×12&#39;s, although the lumber torque tool can be modified for other size lumber. 
     In one form, the lumber torque tool is constructed substantially of metals such as steels, steel alloys, and aluminum. 
     In one form, a lumber torque tool comprises a lever arm formed from an elongate lever arm body. 
     In one form, the lever arm body comprises a proximal face on a proximal end and a distal face on a distal end. 
     In one form, the lever arm body extends along an Axis A. 
     In one form, the lever arm body has a cross-sectional profile that is substantially rectangular. 
     In one form, the elongate lever arm body comprises a substantially planar or flat inner lever face and a substantially planar outer lever face. A first lateral face and an opposed second lateral face extend between the inner lever face and outer lever face. 
     In one form, the inner lever face and the outer lever face are longer than the first lateral face and second lateral face. 
     In one form, the proximal end of the elongate lever arm body comprises one or more grip recess in the form of a recess in the first and/or second lateral faces. 
     In one form, a handle covers the proximal end of the elongate lever arm body. 
     In one form, the handle is constructed of a polymer. 
     In one form, the handle is seated in the one or more grip recesses. 
     In one form, the handle comprises an inner handle surface defining a handle cavity operable for seating the proximal end of the elongate lever arm body therein. 
     In one form, a handle window extends through the handle and the lever arm body at a proximal end and is sized and shaped for receiving a support element such as a nail or a tie. 
     In one form, the lumber torque tool comprises a torque link. 
     In one form, the torque link comprises a torque link body. 
     In one form, the torque link body is in the form of an elongate angle. 
     In one form, the torque link body comprises a first end surface at one end, and an opposing second end surface at an opposing end. 
     In one form, a proximal edge on the torque link faces proximally extending from the first end surface to the second end surface. 
     In one form, one or more distal surfaces on the torque link face distally and extend from the first end surface to the second end surface. 
     In one form, the first end surface is secured to the inner lever face of the lever arm. 
     In one form, welds are utilized to fix component together in the lumber torque tool. 
     In one form, the second end surface is secured to a medial face of an alignment plate. 
     In one form, a lumber torque tool comprises a spur operable for plunging into a side of a joist. 
     In one form, the spur extends from the proximal edge of the torque link along a proximal axis E. 
     In one form, axis E is substantially parallel to axis A. 
     In one form, the spur comprises a substantially cylindrical spur body defined by a spur outer surface. 
     In one form, the proximal end of the spur has a tapered spur face terminating in a spur point substantially centered between the first end surface and second end surface. 
     In one form, the alignment plate comprises an alignment plate body having a substantially broad and flat medial face and an opposed lateral face. 
     In one form, the alignment plate is substantially square or rectangular. 
     In one form, corners of the alignment plate are filleted. 
     In one form, the alignment plate is substantially square and joining the flat medial face and opposed lateral face is a distal facet facing distally, a proximal facet facing proximally, a first lateral facet facing laterally with an opposed second lateral facet also facing laterally. 
     In one form, the inner lever face, proximal edge, and medial face define a proximal torque pocket. 
     In one form, the proximal torque pocket is U-shaped. 
     In one form, the inner lever face, the distal surface, and medial face define a distal torque pocket. 
     In one form, the distal torque pocket is U-shaped. 
     In one form, a wood frame assembly can contain joists, studs, or both joists and studs. 
     In one form, a twisted joist or stud in a wood frame assembly is straightened by plunging a spur from a lumber torque tool into the underside of a joist thereby cupping the bottom face of the joist in the proximal torque pocket. Then applying a counter force to the handle in a direction that removes the twist and into the desired alignment. Then securing the untwisted board with fasteners through a rim joist or joist hanger. 
     In one form, fasteners herein include bolts, screws, and nails and other such devices known in the art. 
     In one form, a twisted joist or stud of a wood frame assembly is straightened by cupping the top face of the joist in the distal torque pocket and applying a counter force to the handle in a direction that removes the twist, then securing the joist or stud with fasteners through a rim joist or joist hanger. 
     In one form, the lumber torque tool eliminates crook in deck boards by plunging the fulcrum spur into the underside of the joist and pulling the warped deck member into the desired alignment with the adjacent deck member using the lever arm and then fastening it. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       These and other features and advantages of the present invention will become more readily appreciated when considered in connection with the following detailed description and appended drawings, wherein each drawing is according to one or more embodiments shown and described herein, and wherein: 
         FIG. 1  depicts a side view of a lumber torque tool in an operable configuration ready for use; 
         FIG. 2  depicts a back view of the lumber torque tool of  FIG. 1 ; 
         FIG. 3  depicts a front view of the lumber torque tool of  FIG. 1 ; 
         FIG. 4  depicts a perspective view of the lumber torque tool of  FIG. 1 ; 
         FIG. 5  depicts an opposed perspective view of the lumber torque tool of  FIG. 1  with handle removed; 
         FIG. 6  depicts an exploded view of the lumber torque tool of  FIG. 1 ; 
         FIG. 7  depicts a close-up perspective view of the distal end of the lumber torque tool of  FIG. 1 ; 
         FIG. 8  depicts a close-up side perspective view of the lumber torque tool of  FIG. 1 ; 
         FIG. 9  depicts a top perspective view of a lumber torque tool engaged with the end of a warped joist; 
         FIG. 10  depicts a top perspective view of the lumber torque tool of  FIG. 9  after a force has been applied to the lumber torque tool thereby removing the warpage from the joist; 
         FIG. 11  depicts a bottom perspective view of the lumber torque tool engaging the bottom of the joist or stud in a proximal torque pocket of the tool; 
         FIG. 12  depicts a close-up perspective view of the spur of the lumber torque tool engaging the surface of the joist; 
         FIG. 13  depicts a close-up perspective view of the lumber torque tool engaging a warped joist from a top surface of a joist in the distal torque pocket of the tool; 
         FIG. 14  depicts a top perspective view of a lumber torque tool engaging a joist to remove crook in decking; 
         FIG. 15  depicts a bottom perspective view of a lumber torque tool engaging a joist to remove crook in decking; 
         FIG. 16  depicts another top perspective view of a lumber torque tool engaging a joist to remove crook in decking. 
         FIG. 17  depicts a flow diagram of a method for removing joist twist using a lumber torque tool. 
         FIG. 18  depicts a flow diagram of a method for reducing crook in a decking board using a lumber torque tool. 
     
    
    
     DETAILED DESCRIPTION OF SELECTED EMBODIMENTS OF THE INVENTION 
     Select embodiments of the invention will now be described with reference to the Figures. Like numerals indicate like or corresponding elements throughout the several views and wherein various embodiments are separated by letters (i.e.  100 ,  100 B,  100 C). The terminology used in the description presented herein is not intended to be interpreted in any limited or restrictive way, simply because it is being utilized in conjunction with detailed description of certain specific embodiments of the invention. Furthermore, embodiments of the invention may include several novel features, no single one of which is solely responsible for its desirable attributes or which is essential to practicing the invention described herein. 
     Disclosed herein are carpentry tools and their methods of use that are designed to subdue warpage in lumber. 
       FIGS. 1-8  illustrate a variety of front, back, side, and perspective views of a preferred embodiment of a lumber torque tool utilized to straighten lumber during the construction of a wood frame assembly such as a deck. The lumber torque tool  100  comprises a lever arm  102  operable to create torque in the tool by hand force. The lumber torque tool  100  is formed from an elongate lever arm body  104  as illustrated in  FIG. 2  along axis A. The lever arm body  104  comprises a proximal face  110  facing proximally on a proximal end and a distal face  112  facing distally on a distal end. The elongate lever arm body  104  comprises a substantially planar and/or flat inner lever face  106  and a substantially planar outer lever face  108 . A first lateral face  114  and an opposed second lateral face  116  extend between the inner lever face  106  and outer lever face  108 . The lever arm body  104  is substantially rectangular in cross-section, however it is recognized that other cross-sectional shapes can be used without disrupting the intent or function of the invention. The outer lever face and inner lever faces make up the longer faces of the rectangular cross-section. 
     The proximal end of the elongate lever arm body  104  comprises one or more grip recess  184  in the form of a recess in one or more of the first lateral face  114  and second lateral face  116 . A handle  170  covers the proximal end of the elongate lever arm body  104 . The handle is seated in the one or more grip recess  184 . Handle  170  comprises an inner handle surface  174  defining a handle cavity  178  operable for seating the proximal end of the elongate lever arm body  104  therein. When present, a handle window  180  extends through the handle  170  and the lever arm body  104  at a proximal end. 
     As also illustrated in the Figures according to one embodiment, the lumber torque tool  100  comprises a torque link  118  comprising a torque link body  120 . The torque link body  120  is in the form of an elongate angle having a first end surface  122  at one end, and an opposing second end surface  124  at an opposing end. A proximal edge  126  on the torque link  118  faces proximally and extends from the first end surface to the second end surface. In addition, one or more distal surfaces  128  on the torque link face distally and extend from the first end surface  122  to the second end surface  124 . The first end surface  122  is secured to the inner lever face  106  of the lever arm  102  whereas, the second end surface  124  is secured to a medial face  154  of an alignment plate  150 . 
     As best illustrated in  FIG. 8 , lumber torque tool  100  comprises a spur  136  operable for plunging into an edge of a joist or stud during construction of a wood frame assembly. As illustrated, the spur  136  extends proximally and generally perpendicular to and from the torque link body  120  from the proximal edge  126  of torque link  118 . In this embodiment, spur  136  comprises a substantially cylindrical spur body  138  defined by a spur outer surface  144  and the proximal end of the spur  136  has a tapered spur face  142  terminating in a spur point  140 . The spur  136  is preferably centered between first end surface  122  and second end surface  124 . Although angled, it is recognized that the torque link  118  can assume other cross-sectional profiles such as square and continue to be operable. Similarly, although having a cylindrical body in this embodiment, it is recognized that the spur  136  can assume other cross-sectional profiles and remain functional. As illustrated in  FIG. 7 , spur  136  can be seated in a spur hole  146  extending through the torque link from a proximal edge  126  and welded into position. Welds, fasteners, and other well know approaches in the art can be used to secure the various parts of the lumber torque tool together. 
     As noted in  FIG. 4  and other Figures, alignment plate  150  comprises an alignment plate body  152  having a substantially broad and flat medial face  154  and an opposed lateral face  156 . The alignment plate  150  in this embodiment is substantially square (although other shapes can be used) with rounded corners. Joining the flat medial face and opposed lateral face is a distal facet  158  facing distally, a proximal facet  160  facing proximally, a first lateral facet  162  facing laterally with an opposed second lateral facet  164  also facing laterally. 
     As further illustrated in  FIG. 4 , the inner lever face  106 , proximal edge  126 , and medial face  154  define a substantially U-shaped proximal torque pocket  166  operable for coupling around and applying torque to a board. The inner lever face  106 , the distal surface  128 , and medial face  154  define a substantially U-shaped distal torque pocket  168  operable for coupling around and applying torque to a board. In preferred embodiments, the medial face and inner lever face are spaced at least 1.5 inches. 
     One embodiment of a method of use of a lumber torque tool  100  is illustrated in  FIGS. 9-12  during the building of a wood frame assembly  200 . The flow diagram in  FIG. 17  also illustrates this method in greater detail. The method is directed to wood frame assemblies whereas the term ‘joist’ can refer to both joists and studs. The wood frame assembly illustrated in  FIG. 9  is used as an example, however the lumber torque tool can be used in wood frames having countless variations. In a first step, assembly of a wood frame is initiated ( 228 ). The wood frame assembly  200  of  FIG. 9  comprises a series of spaced joists including outer joists  204  and inner joists  206  which are secured on the ends by a rim joist  202  and further secured with fasteners  208  extending through the rim joist  202  and into the outer joists or inner joists or secured in straightened orientation using a joist hanger. In this embodiment, a first end of the joist is aligned with a rim joist  202  and secured in position with fasteners  208  or a joist hanger ( 230 ). The free end (unsecured) of the twisted joist is secured with one fastener in the desired position ( 232 ). A lumber torque tool as described herein is obtained ( 234 ). The location of the twisted joist is evaluated to determine if adequate clearance is available below the joist to engage the unsecured end of the joist within the proximal torque pocket  166  of the lumber torque tool  100 . If the clearance is sufficient, the lumber torque tool  100  is positioned such that the targeted joist is seated in the proximal torque pocket  166 , and optionally the spur  136  of the lumber torque tool  100  is plunged on the underside of the joist as illustrated in  FIGS. 9, 12  ( 236 ). A force is applied to the lever arm  102  in a direction that reverses the twist as illustrated in  FIG. 10  ( 240 ) to align the joist  206  with the plum line  214  marked on the rim joist  202  (joist header) where it is held in an un-twisted position. The remaining fasteners  208  extending through the rim joist  202  adjacent the unsecured end of the un-twisted joist are then advanced ( 242 ) to hold the joist untwisted in the wood frame assembly  200  or optionally, a joist hanger is utilized to secure the joist in the un-twisted position. 
     The distal torque pocket  168  of the lumber torque tool  100  can be utilized when the distal edge of a twisted joist cannot be seated in the proximal torque pocket  166  due to limited access as evaluated at step ( 236 ). This may occur for example when building a wall unit or other wood frame assembly ( 228 ) on a deck, or driveway, or when there is otherwise insufficient ground clearance between the distal edge of the joist and the ground. The torque required to un-twist the joist or stud is then applied from the top of the joist  206  as illustrated in  FIG. 13 . One end of the joist  206  or stud is aligned and then secured into position at the rim joist  202  ( 230 ). The free, unsecured end is then aligned and secured with one fastener ( 232 ). The twisted framing member is then straightened by cupping the top face of the joist/stud in the distal torque pocket ( 238 ) and applying a counter force to the handle in a direction that un-twists the member into alignment with the intended plum line ( 240 ). The un-twisted framing member is then secured with screws or nails through the rim joist  202  (joist header) or with a joist hanger ( 242 ). 
       FIGS. 14-16  illustrates the method of using a lumber torque tool  100  to eliminate crook in decking. As noted in the Figures, deck boards  210  (first deck board  216 , second deck board  218 ) are being secured to the top surfaces of joists  206 , outer joists  204 , and rim joists  202  during construction of a wood frame assembly  200  to support decking. As evidenced by the curve in the board, the third deck board  220  is illustrated with crook warpage prior to being fastened into position. Note, the fasteners  208  are positioned and have yet to be sunk. In this method, one or more deck boards  210  such as a first deck board  216  and second deck board  218  are fixed to the wood frame assembly as illustrated using fasteners  208 . A third deck board  220  is then placed adjacent one of the fixed deck boards on the wood frame assembly ( 254 ). Deck spacers  212  are temporarily placed between the warped board and the fixed (secured) board adjacent to it ( 256 ). The spacers have a thickness representative of the width of gap desired between the deck boards. A lumber torque tool as disclosed herein is obtained ( 258 ). The lumber torque tool  100  is then positioned with the bottom of a joist  206  seated in proximal torque pocket  166  and with spur  136  plunged into the underside of the joist ( 260 ). A counter force is then applied to the handle  170  with the first lateral face  114  or second lateral face  116  driving the warped third deck board  220  into the desired alignment with the adjacent deck member using the lever arm thereby removing crook ( 262 ). The fasteners  208  are then advanced into position to hold the deck board  210  in place ( 264 ). The deck spacers  212  can then be removed ( 266 ). 
     It is noted that the terms “substantially” and “about” and “generally” may be utilized herein to represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. These terms are also utilized herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue. 
     The foregoing invention has been described in accordance with the relevant legal standards, thus the description is exemplary rather than limiting in nature. Variations and modifications to the disclosed embodiment may become apparent to those skilled in the art and fall within the scope of the invention.