Patent Publication Number: US-6705059-B2

Title: Rolled fabric carriage apparatus

Description:
FIELD OF INVENTION 
     This invention relates to apparatus which is capable of rotatably carrying a fabric roll in a vertical orientation along an element of a known fabricated wall structure. More specifically, this invention relates to apparatus which is useful in the practice of dispensing a sheet of vapor retarding fabric when constructing insulated fabricated wall structures. 
     BACKGROUND OF INVENTION 
     In the fabricated building art, it has been known to construct and insulate roof and wall structures utilizing various methods and apparatus such as is disclosed in my U.S. patent application Ser. No. 09/511,305 filed February 23, 2000, now U.S. Pat. No. 6,308,489, which discloses apparatus for dispensing a layer of fabric along a frame of a wall structure (as well as on roof structures). Such layer of fabric typically serves as a support layer for a thickness of insulation and often as a vapor barrier to prevent moisture from penetrating the various spaces and materials of the wall (or roof) structure. 
     Fabricated wall structures are conventionally comprised of a series of wall studs or columns extending vertically from a cement foundation with various girts or purlins mounted on the outside facing surface substantially perpendicular thereto (i.e. in a substantially horizontal fashion). A typical spacing of these girts is approximately 5 feet from centerline to centerline, however any desired spacing may be employed. Typically located at the bottom of the wall structure, usually attached, in known fashion, to the foundation of the building, is a base angle which is conventionally L-shaped with a horizontally extending base portion and a vertically extending back portion oriented at a right angle to the base portion. The base portion of the “L” is typically attached flush with the horizontal surface of the foundation with the vertical portion of the “L” usually being oriented in-line with the vertical edge of the foundation. Located as such, the vertical portion of the base angle provides a surface to which metal wall panels may be attached such as by screws or other mechanical means. Typically, there is a space between the upper most edge of the base angle and the first girt (or purlin), the size of such space approximating the distance between any two girts or purlins. 
     In order to insulate such a conventional wall structure, it is known to first dispense a layer of fabric (e.g. such as a high-density-woven-polyethylene) over the outermost surface of the girts (i.e. the surface which would normally face the outside of the building). After securing at least a first (i.e. trailing) end of the fabric, batts of insulation are placed on top of this fabric layer and a layer of wall panels (e.g. metal sheeting) placed thereover. Once the metal sheeting is in place, the metal sheeting is secured or fixed to the girts and base angle of the wall structure using mechanical means such as conventional fastening screws. 
     In order to facilitate efficient construction and insulation of such a wall structure, apparatus may be used such as described in U.S. patent application Ser. No. 09/511,305 to secure a fabric roll against the framework of the wall structure (i.e. the girts) as the fabric is being dispensed. Apparatus for this purpose are particularly important in fabricating insulated walls because of the rather large size and weight of fabric rolls and their rather unwieldy nature when positioned in vertical orientations. Known wall dispenser apparatus, however, only secure the fabric rolls so as to prevent the fabric rolls from falling away from the wall frame and do not provide support for rolls at their bottom most ends (i.e. they are incapable of supporting fabric rolls above ground or foundation level). Therefore, without further apparatus to aid in vertically carrying a fabric roll, the roll will remain in contact with the ground (if not otherwise carried, for example) and may only be advanced along the length of the wall with much difficulty and with possible damage to the end of the roll from contact with rocks or other abrasive materials or surfaces. 
     One attempt to solve the above described problem is disclosed and illustrated in the above-referenced pending patent application. In this attempt to solve the prior art problem, a ball is inserted into the core of the bottom most end of the fabric roll thus providing a surface for contact with the ground. This ball, then, supports substantially the entire weight of the fabric roll and aids in the movement of the roll around the perimeter of the building structure. Although useful, such a ball has its own disadvantages. In particular, one problem associated with the use of such device is that if a relatively flat or even surface is not encountered by the ball structure, a roll of fabric may not be advanced in a smooth, trouble free manner. In this respect, such ball type devices require a substantially smooth ground surface surrounding the foundation of the building if they are to be effective at all. Because such a smooth ground surface is needed, valuable time and effort must be expended in order to clear the areas surrounding the building of rocks and other obstructing debris. 
     In view of the above, it is apparent that there exists a need in the art for apparatus which overcomes the above drawbacks. It is a purpose of this invention to fulfill this need in the art, as well as other needs which will become apparent to the skilled artisan once given the above disclosure. 
     SUMMARY OF INVENTION 
     Generally speaking, this invention fulfills the above-described needs in the art by providing: a carriage apparatus for carrying a roll of fabric as the roll of fabric is being dispensed along a wall structure, the carriage apparatus comprising: 
     a first frame member; 
     a second frame member extending at a first angle from the first frame member; 
     means for rotatably carrying a fabric roll in a substantially vertical orientation, the mean for rotatably carrying a fabric roll located proximal a first surface of the first frame member; 
     first means for contacting a first surface of a building element, the first means located proximal a second surface of the first frame member; 
     second means for contacting a second surface of the same or a different building element, the second means located proximal a first surface of the second frame member; and 
     wherein the first and second means for contacting, in combination, are capable of cooperating with at least one element of a building structure such that the carriage apparatus will be moveably engaged to the at least one element 
     In another embodiment there is provided: a carriage apparatus for carrying a roll of fabric as the roll of fabric is being dispensed along a wall structure, the carriage apparatus comprising: 
     a first frame member having a first and a second surface; 
     a second frame member extending at a first angle from the first frame member; 
     a rotatable carrying member attached proximal the first surface of the first frame member and being capable of supporting a roll of fabric in a vertical orientation; 
     a first contacting member attached proximal the second surface of the first frame member; 
     a second contacting member attached proximal a first surface of the second frame member; 
     wherein the first and second contacting members, in combination, are capable of cooperating with at least one element of a building structure such that the carriage apparatus will be moveably engaged to the at least one element 
    
    
     IN THE DRAWINGS 
     FIG. 1 is three-dimensional view of a prior art dispenser employed dispensing a sheet of fabric along a known wall structure. 
     FIG. 2 is a three-dimensional view of the prior art dispenser of FIG.  1 . 
     FIG.  3 . is a three-dimensional view of one embodiment of a carriage apparatus according to the subject invention. 
     FIG. 4A is a side-view of the carriage apparatus of FIG. 3 shown in operation on a wall structure. 
     FIG. 4B is a side-view of an alternative embodiment of the carriage apparatus of FIG.  4 A. 
     FIG. 4C is a side view of an alternative embodiment of the carriage apparatus of FIG.  4 A. 
     FIG. 5 is a is a three-dimensional view of the carriage apparatus of FIG. 3 shown in use dispensing fabric along a known wall structure. 
    
    
     DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS 
     With reference first to FIG. 1, there is illustrated a conventional fabricated wall structure  29  in the process of being insulated utilizing a combination of known prior art apparatus. In particular, FIG. 1 illustrates a known rolled fabric dispenser  100  being utilized to dispense a vapor retarding fabric sheet  91  (along wall structure  29 ) from a roll of fabric  90 . This fabric dispensing step, as previously described in the Background section above, is the first step in the insulated wall fabrication process. The remaining steps, as well as dispenser  100 , are described in detail herein below but are more fully described in the aforementioned U.S. Pat. No. 6,308,489. 
     As previously described, wall  29  is generally comprised of a series of spaced, vertically extending columns (or studs)  25 . These columns are set in foundation  23  typically several inches back from the edge of the foundation. Attached thereto are a plurality of horizontally disposed girts  31 , each extending substantially parallel one to the other. These girts  31 , as may be seen in FIG. 1, are the surface upon which fabric from fabric roll  90  will be dispensed. Each girt is typically comprised of a top flange  33 , a bottom flange  37 , and a web portion  35  extending between and connecting the two flanges. The distance between top flange  33  and bottom flange  37  is roughly equal to the distance columns  25  are usually set back from the edge of the foundation  23 . 
     Further typically included in such a conventional wall structure, as aforedescribed, is base angle  21  which is normally “L” shaped with the base (horizontal portion) of the “L” being fixed flush against the top surface  23 ′ of the (typically cement) foundation  23 . The vertical portion of the “L” structure, as shown, is aligned with the vertical edge (or end) of the foundation. Although base angles come in a variety of dimensions, the base angle employed as illustrated is approximately 2 inches×2 inches. 
     In order to efficiently insulate such a fabricated wall structure as illustrated, dispenser  100  may be employed in known fashion to secure the rather long and heavy fabric roll  90  tight against the surface of the girts in a vertical position (FIG.  1 ). Use of dispenser  100  ensures that fabric (as sheet  91 ) may be dispensed in a manner so that the relative tautness or non-tautness of the sheet  91  may be controlled. Methods and uses for controlling the tautness or non-tautness of the insulated fabric are disclosed in detail in my co-pending U.S. Patent Application No. 09/511,306, filed Feb. 23, 2000, now U.S. Pat. No. 6,393,4897. 
     Referring now to FIG. 2, dispenser  100  and its functionality are illustrated in more detail therein. As may be seen in this figure, dispenser  100  generally includes a frame member  101 , a roll retention member  111  for holding a roll of fabric securely against a surface of girts  31 , and a biasing mechanism  103  (including a coil spring  104  and glide plate  105 ) for securing the dispenser  100  to a surface of the wall structure and thus roll  90  via retention member  111 . In particular, in order to set up dispenser  100  on a wall structure, guide mechanism  109  is placed over a girt  31  and push plate  115  is manipulated to orient glide plate  105  at the undersurface  33   a  of a girt top flange  33 . So oriented, the force of coil spring  104  (resulting from its compression) is sufficient to maintain glide plate  105  in biasing engagement with undersurface  33   a  and thus secure dispenser  100  to the surface of the wall structure. As may also be seen in this figure, biasing mechanism  103  may be disassembled and reassembled in either of tubular arms  107   a  or  107   b  (via the removal of push plate  115  and wing nut  119 ), thus allowing dispenser  100  to be set up on any orientation of top flange  33  which is encountered. 
     As described in detail in the aforesaid co-pending application Ser. No. 09/511,306, dispenser  100  is useful for efficiently dispensing rolled fabric on both fabricated roof and wall structures. When employed to dispense fabric on a wall structure, however, dispenser  100  should ideally be used in combination with additional apparatus which is not subject to the aforementioned problems in the art. If such additional apparatus is not used, the end of the fabric roll  90  will drag on the ground  19  (and contact rocks and dirt, for example). 
     Turning now to FIGS. 3,  4 A,  4 B,  4 C, &amp;  5 , there is illustrated apparatus which uniquely and efficiently overcomes the aforesaid drawbacks of the prior art. Specifically, carriage apparatus  1  (illustrated in these figures) solves the problems of the art by 1) supporting fabric roll  90  itself above ground level, and 2) by not contacting the ground itself and therefore not suffering the disadvantages associated therewith. 
     As illustrated in these figures, rolled fabric carriage apparatus  1  generally includes a frame  7  comprised of a first frame member  3 , and a second frame member  5  extending vertically at an approximately 90 degree angle therefrom. Attached to first frame member  3  is rotatable carrying member  9  which, in the present embodiment, is generally cylindrical in shape. More particularly, in some embodiments carrying member  9  is preferably sized so that its outside diameter is slightly smaller than the inside diameter of core  89  of fabric roll  90  (see FIGS.  4 A and  4 C). This allows for carrying member  9  to be inserted into core  89  so that roll  90  will not shift unnecessarily when carried by carriage  1 . In order that fabric roll  90  be capable of unrolling i.e. dispensing fabric as dispenser  100  is advanced along a wall structure, carrying member  9  is preferably rotatably attached to first frame member  3  via a rotatable attachment portion  9   a  and associated bearings (not shown). Carrying member  9  may, of course, take any variety of alternative forms so long as such forms permit carriage  1  to rotatably support a fabric roll. 
     Included as part of carriage apparatus  1  as means for attaching carriage  1  to a base angle  21  is a pair of first contacting members  11  and a pair of second contacting members  13 . As seen in FIG. 4A, these contacting members are so oriented by their attachment, respectively, to first and second frame members  3  and  5  (via flanges  14  and arms  15 ) such that carriage apparatus  1  may be placed over the vertical portion of “L” shaped base angle  21  so that second contacting members  13  will contact surface  21   a  of the base angle, and first contacting members  11  will contact vertical surface  23   a  of the foundation (FIG. 4 a ). Abutting the respective surfaces of the base angle and foundation as such, first and second contacting members  11  and  13  effectively support carriage apparatus  1  at a predetermined height above ground level i.e. ground  19  (see FIG.  5 ). 
     In an alternative embodiment illustrated in FIG. 4B, first contacting members  11  may be so located so as to contact surface  21   b  of base angle  21  (e.g. if frame member  5  is of smaller dimensions for example). In a further alternative embodiment, illustrated in FIG. 4C, arms  15  may be of such a length such that contacting members  13  abut against surfaces  21   c  and  21   d  of the vertical and horizontal surfaces of the base angle respectively (i.e. between the angle formed by the vertical and horizontal members). 
     Contacting members  11  and  13  should be designed, of course, so that they allow carriage apparatus  1  to move unencumbered and smoothly along the perimeter of the wall structure via their engagement with base angle  21  and, in some embodiments, foundation  23 . In this regard, in the embodiments illustrated in FIGS. 3,  4 A,  4 B,  4 C, and  5 , contacting members  11  and  13  are simply wheels attached to respective frame members  3  and  5  (by flanges  14  and arms  15 ) via rods  11   a  and  13   a  with associated bearings (not shown) to allow for rotatability. Alternatively, these wheels may be replaced by a low-friction plate, for example, or by any other suitable material or known structure which will allow carriage  1  to travel easily along base angle  21 . 
     Referring again to FIG. 4C, in a still further alternative embodiment, frame member  5  is constructed so as to be adjustable in length. In particular, frame member  5  is made adjustable so that carriage apparatus  1  may be installed on a variety of base angles having varying dimensions. Rendering frame member  5  adjustable (in this embodiment) are frame member plates  5   a  and  5   b  which may be shifted up or down with respect to each other and a bolt  5   c  inserted therethrough (i.e. through apertures in each) to fix a particular frame member  5  length. 
     In the use of the subject invention, therefore, in order to efficiently and easily dispense fabric along a wall structure  29 , carriage apparatus  1  may be employed by first placing it so that contacting members  13  engage surface  21   a  of the base angle (or in alternative embodiments surfaces  21   c  and  21   d ). Appropriately positioned, contacting members  11  should now be rested (as aforesaid) against surface  23   a  of the foundation, or, in other embodiments, surface  21   b  of the base angle (as shown in FIGS. 4A and 4B respectively). Once carriage apparatus  1  is correctly engaged with base angle  21  as such, a roll of fabric  90  may be loaded thereon. This may be accomplished by simply lifting a roll  90  and placing core  89  over rotatable carrying member  9  such that carrying member  9  inserts thereinto (see FIGS.  4 A and  4 C). Thereafter, in order to secure roll  90  tightly against girts  31 , rolled fabric dispenser  100  may be employed by manipulating push plate  115  to orient glide plate  105  of biasing mechanism  103  behind a girt top flange  33 . Dispenser  100  should be attached in a manner, of course, so that roll retaining member  111  is oriented over roll  90  and holds it firmly against the surface of the girts  31  via the force of coil spring  104  of biasing mechanism  103  (see FIG.  5 ). Before dispenser  100  is attached to secure roll  90 , the roll may be manually held in place by another installer/worker. 
     It is noted here that the particular order of steps to mount a roll  90  upon a wall structure in preparation for fabric installation is not particularly important, and a roll  90  may be first loaded onto dispenser  100  and loaded onto carriage apparatus  1  thereafter if the installer desires. Furthermore, an installer need not employ the specific embodiment of dispenser  100  as illustrated in order to practice within the scope of the subject invention. As an alternative, any other embodiment of a rolled fabric dispenser may be employed, such as illustrated and described in U.S. Pat. No. 6,247,288 issued to Dan Harkins on Jun. 19, 2001, or no rolled fabric dispenser employed at all. 
     When utilizing dispenser  100 , however, once a roll is loaded onto carriage apparatus  1  and dispenser  100  is in place on an appropriate girt  31 , the fabric dispensing operation may be commenced. In particular, push pole  113  may be inserted into an end of frame  101  and utilized to advance dispenser  100  along the length of the wall surface (see FIG.  5 ). As dispenser  100  is pushed forward (after the trailing end of the fabric has been secured by conventional means such as with tape or adhesive), roll  90  will turn within roll retention member  111  allowing fabric to dispense as sheet  91  along the wall surface. Carriage apparatus  1 , of course, carries the roll  90  above ground level  19  and along the wall length meanwhile allowing roll  90  to easily dispense sheet  91  via the rotatability of carrying member  9 . Batts of insulation may then be placed over the layer of fabric  91  and metal sheeting fixed by screws or other mechanical means thereover. 
     Once given the above disclosure, many other features, modifications, and improvements will become apparent to the skilled artisan. Such other features, modifications, and improvements are therefore considered to be part of this invention, the scope of which is to be determined by the following claims: