CONSTRUCTION PANEL POSITIONING AND SUPPORT SYSTEM AND TOOLS

Abstract

A construction panel support tool includes a suspension frame having a mounting member to mount the tool to a ceiling joist adjacent a construction panel installation site and a guide member coupled thereto. An elongate support member movably supported on the guide member is movable relative thereto between a deployed position in which a distal portion of the support member extends beneath the panel installation site, and a standby position. The tool may include a locking member selectively engageable to retain the support member in a desired position, such as a deployed position, and may optionally include a biasing member selectively engageable to bias the distal portion of the support member toward the panel installation site.

Description

TECHNICAL FIELD

The disclosure relates to building construction, and in particular to tools to assist lifting and supporting construction panels in position for installation.

BACKGROUND

In building construction in the U.S., it is conventional to install sheets of drywall and other types of construction panels (such as plywood, paneling, other forms of wall sheeting, and so forth) to ceiling and wall joists, However, construction panels can be large and somewhat cumbersome to position for installation. Drywall, for example, is typically composed of a layer of crushed gypsum pressed between two sheets of thick paper. A standard sheet of drywall is usually 4′ by 8′, or 4′ by 12′, in size, and generally weighs between about 50 to 110 pounds, depending on its constituent materials and dimensions. When drywall and other construction panels are installed to walls and ceilings, it is often necessary for one or more workers to hold the panel in place while others nail or screw it to the underlying joists or supports,

Construction panel lifts, which are sometimes referred to as drywall jacks in drywall-specific applications, are not satisfactory for the range of applications in which they are employed. For example, existing lifts generally include a number of articulating components and/or are complex to maneuver and operate, and in general are quite cumbersome. Further, some lifts do not significantly decrease the labor expense of positioning by hand, because many require one person to attend to the lift at all times to maintain the construction panel in a desired position, while another worker fastens the panel to the installation site. Lacking a second worker, the use of conventional construction panel lifts by a solo worker risks injury and/or inaccurate positioning or installation of a panel.

SUMMARY

Illustrative embodiments of construction panel positioning tools and construction panel support tools, and construction panel positioning and support systems employing two or more of such tools, are disclosed herein. An illustrative embodiment of a construction panel positioning tool to position and support at least one edge of a construction panel relative to a panel installation site includes a ramp member and a stabilizing member coupled thereto. The ramp member includes a support platform disposed at an upper end thereof and having an upper surface to receive and support at least an edge portion of a construction panel, and a ramp section adjacent the support platform and extending downward at an angle therefrom. The ramp section is configured to slidingly engage and guide an edge of a construction panel placed thereon toward the support platform, with which it shares a common edge. The stabilizing member is configured to be temporarily secured to or otherwise engage a structural component of a building structure, such as a wall or ceiling joist, to support the ramp member in position. In some panel tool embodiments, the stabilizing member includes a vertical brace, such as to engage and/or be secured to one or more wall joists, with the ramp section projecting at an angle away from the wall joist. When installed with the support platform near ceiling joists, such embodiments may be used to position and then temporarily support an edge of a construction panel in position for installation to the ceiling joists. In some panel tool embodiments, the stabilizing member includes a horizontal brace, such as to engage and/or be secured to one or more ceiling joists,

Illustrative embodiments of a construction panel support tool to temporarily support a construction panel relative to a panel installation site includes a suspension frame and an elongate support member coupled thereto. In a first illustrative embodiment, the suspension frame includes elongate top and bottom guide members collectively configured to slidably engage all four sides of a ceiling joist, and the support member cantilevers away from the suspension frame, and includes a top surface that is spaced, with respect to a ceiling joist with which the suspension frame is engaged, to provide temporary support of a construction panel to the ceiling joist. in a second illustrative embodiment, the suspension frame includes a mounting member adapted to mount the tool on a ceiling joist, and a guide member coupled thereto, with the support member movably supported on the guide member for movement between a deployed position (in which the support member provides support of a construction panel relative to a panel installation site) and a standby position.

in use, an illustrative embodiment of a construction pen el positioning and support system, which includes one or more construction panel positioning tools and one or more construction panel support tools, may be used, such as by an individual worker to assist in maneuvering and holding construction panels in position for installation, for example to ceiling joists in order to form a ceiling. For example, one or more panel positioning tools with vertical stabilizing members may first be fastened to wall joists so the support platforms are near the ceiling joists. A construction panel, such as a sheet of drywall, may be placed with a first or forward edge on the ramp section(s) of the positioning tool(s) and slid upward so the forward edge is supported on the support platform(s) thereof. With the forward edge supported, the worker may lift the opposite edge toward the ceiling joists. A panel support tool suspended on a nearby ceiling joist may then be slid therealong so the support member extends below the construction panel, providing vertical support so the worker can then install the construction panel. The positioning tool(s) may then be removed and the support tool moved away from the installed panel. To install a second panel adjacent the first, a worker may then fasten one or more panel positioning tools with horizontal stabilizing members to the ceiling joists to which the first panel is installed, and use the ramp sections of the positioning tools in the same manner to raise and then support the forward edge of the second panel in place, lifting the opposite edge up to the ceding, and holding the panel in place by sliding a support member of a panel support tool underneath the panel.

The concepts and components listed above are clarified with reference to the accompanying drawings and detailed description below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a three-dimensional view of a first illustrative embodiment of a construction panel positioning tool constructed in accordance with aspects of the present disclosure, with a vertically-oriented stabilizing member that includes two horizontal arms by which the tool is removably secured to a wall joist.

FIG. 2 shows a front elevation view of the positioning tool of FIG. 1.

FIG. 3 shows a three-dimensional view of a second illustrative embodiment of a construction panel positioning tool constructed in accordance with aspects of the present disclosure, with a horizontally oriented stabilizing member by which the tool is removably secured to a ceiling joist to which a construction panel is installed.

FIG. 4 shows a front elevation view of the positioning tool of FIG. 3,

FIG. 5 shows a three-dimensional view of an illustrative embodiment of a construction panel support tool constructed in accordance with aspects of the present disclosure, having a suspension frame by which the tool is suspended from a ceiling joist. An elongate support member extends partially beneath a construction panel, supporting the panel beneath the ceiling joist.

FIG. 6 shows a three-dimensional view of a second illustrative embodiment of a construction panel support tool constructed in accordance with aspects of the present disclosure, having a suspension frame used to secure the tool to a ceiling joist. An elongate support member movably supported on the frame extends partially beneath a construction panel.

FIG. 7 shows a partial side elevation view of the support tool of FIG. 6, in which the support member is moved into a deployed position.

FIG. 8 shows a side elevation view similar to that of FIG. 7, in which the thumbscrew of the support tool, functioning as a locking member, is engaged with the mounting plate, thereby retaining the support member in a deployed position,

FIG. 9 shows another side elevation view similar to that of FIG. 8, in which the thumbscrew, functioning as a biasing member, biases the distal portion of the support member toward the ceiling joist, urging the construction panel supported thereby toward the ceiling joist.

FIG. 10 shows a partial side elevation view of a construction panel positioning tool, such as shown in FIG. 1, as part of a construction panel positioning and support system, in which the positioning tool is removably secured to a wall joist, and in which a forward edge of a construction panel is shown to be guided upward along the ramp section of the positioning tool,

FIG. 11 shows a side elevation view of the positioning tool of the positioning and support system partially shown in FIG. 10, in which the forward edge of the construction panel is shown to have been guided onto the support platform of the positioning tool.

FIG. 12 shows a side elevation view of the positioning and support system partially shown in FIGS. 10 and 11, now including a construction panel support tool, shown to be moved so that the elongate support member thereof extends beneath the construction panel to support it in place for installation.

FIG. 13 shows a side elevation view of the positioning system partially shown in FIGS. 10-12, now including a second construction panel positioning tool, such as shown in FIG. 3, in which the positioning tool is secured to the ceiling joist to which a construction panel is installed, and in which a forward edge of a second construction panel is shown to be guided upward along the ramp section of the positioning tool.

DETAILED DESCRIPTION

A construction panel positioning and support system 50, which includes one or more construction panel positioning tools (indicated generally at 10) and one or more construction panel support tools (indicated generally at 40), and example embodiments of the individual tools thereof, is shown in FIGS. 1-13. As described in greater detail below, the tools of the system are collectively and individually adapted to assist a user in maneuvering and/or temporarily supporting a construction panel, such as a drywall sheet, in a desired position adjacent an installation site, to which it may then be installed.

in general, the positioning tool(s) 10 are each adapted to engage and/or be supported on a structural component of a building structure, such as by being removably or temporarily secured to a wail or ceiling joist, and/or a construction panel already installed thereto. Once supported in place, the positioning tools may facilitate guiding a first edge (also referred to herein as a forward edge) of a construction panel, by means of an inclined ramp section, and then temporarily supporting the panel edge on a support platform in a desired position, such as adjacent to a joist to which the panel will then be installed. The support tool(s) 40 are also each adapted to be supported on a structural component, such as by being movably suspended from, or mounted to, a ceiling joist, and may facilitate supporting a portion of a construction panel, such as a second edge of a construction panel partially supported on one or more positioning tools, by being moved along the joist into a position in which a support member engages the construction panel portion, or by moving the support member into a supporting position beneath a construction panel, depending on the configuration of the support tool. As such, the tools may be used separately, or collectively as a system.

For ease of explanation, the illustrative embodiments of the tools 10, 40 shown and described herein are adapted for use with sheets of drywall to be temporarily supported in a generally horizontal orientation adjacent ceiling joists, prior to installation thereto. However, it will be clear from the following description that the tools may be adapted for use with other types of construction panels as well as drywall sheets, any of which may be installed in a variety of orientations (such as vertical, such as for installation to wall joists, or in an angled orientation, such as for installation to joists or other structural beams or supports forming curved or angled walls or ceilings), without departing from the scope of the invention. As such, for example, the directional terms used in the description below are relative and are provided for the sake of clarity, and should not be considered in a limiting sense.

Also, the illustrative tool embodiments shown and discussed below are prototype embodiments fashioned from pieces of industrial steel, such as square tubing and angle steel and so forth, which have been rigidly welded together, include movable couplings in the manner illustrated, and/or are machined to have the particular characteristics explained herein, Moreover, the specific dimensions, scale, and other measurements thereof are customized for use with standard lumber sizes and construction techniques conventionally used in building construction in the U.S. For example, a wall frame is generally constructed from 2×4 beams of lumber and/or steel braces, with a series of vertical beams (studs) extending between horizontal top and bottom beams (plates). Typically, there are two top plates, one on top of the other, with a parallel series of 2×4 or 2×6 beams extending edgewise across the top plates of opposing wall frames to form the ceiling frame. However, the disclosure should be understood to encompass embodiments that may be constructed to suit other structural beam components or configurations, fabricated from other suitable materials and assembled in other manners, and/or configured to include adjustable or additional/alternative movable linkages between or among various components and parts of the particular tool.

Two illustrative embodiments of a construction panel positioning tool 10 are discussed first with reference to FIGS. 1-4, followed by a discussion of two illustrative embodiments of a construction panel support tool 40, with reference to FIGS. 5-9, The description then proceeds with a discussion of how the tools 10, 40 may be used together as a construction panel positioning and support system 50, with reference to FIGS. 10-13, and concludes by discussing some alternative configurations and/or variants of some of the embodiments, such as to illustrate variations of structural components and arrangement of such components. The various embodiments, configurations, and methods disclosed in the paragraphs below are illustrative and should not be considered in a limiting sense, but merely for purposes of illustrating one or more of the aspects of the subject matter described herein. Numerous variations are possible and considered to be within the scope of this disclosure.

A first, non-exclusive, illustrative embodiment of a construction panel positioning tool 10 is shown in FIGS. 1 and 2 at 100, and a second, non-exclusive, illustrative embodiment is shown in FIGS. 3 and 4 at 200. Both embodiments of positioning tool 10 are adapted to position and support an edge, or edge portion, of a construction panel in a desired position, such as adjacent to an installation site. In particular, positioning tools 100 and 200 are both adapted to support a forward edge of a sheet of drywall in position substantially adjacent to one or more ceiling joists to which the sheet is to be installed. The structural differences between the two illustrative embodiments provide configurations that are each suitable for a different type of installation site. More specifically, positioning tool 100 is an embodiment in which the stabilizing member is adapted to engage a wall component, such as one or more wall joists, and thus may be suitable for a ceiling installation site in which one or more edges of a drywall sheet are to be installed adjacent to a wall. Positioning tool 200, however, is an embodiment in which the stabilizing member is adapted to engage a ceiling component, such as a ceiling joist to which a sheet of drywall has already been installed, and thus may be suitable for a ceiling installation site in which none of the edges of a drywall sheet will be adjacent to a wall.

In general and somewhat functional terms, each of the positioning tool embodiments includes an elongate ramp member 12 coupled to a stabilizing member 14, which is configured to engage a structural building component to thereby support the ramp member in a predetermined position relative to an installation site on the building structure. Ramp member 12 includes a support platform 16 disposed at its upper end, and a ramp section 18 disposed adjacent the support platform 16 and configured to extend downwardly at an angle therefrom. The ramp section 18 includes a substantially planar upper surface 20 configured to slidably engage and subsequently guide a forward edge of a construction panel placed on the ramp section toward the support platform 16. The upper surface of the ramp section has an upper edge 22 in common with an upper surface 24 of the support platform 16, which is configured to receive and support at least the forward edge of the construction panel.

in more specific terms, as can be seen from FIGS. 1 and 2, positioning tool 100 is shown to be constructed from two bars 102, 104 of square steel tubing, which are coupled at the upper ends thereof to form an apex. In particular, the front bar 102 projects forward at an acute angle relative to the rear bar 104, which is shown to be vertically oriented. A crossbar 106, shown as a length of angle steel, is coupled at its center to the apex to extend at right angles to the vertical plane formed by bars 102, 104, with its top plate 108 forming a horizontal plane and its side plate 110 abutting the rear side of the rear bar 104. The side plate 110, which may be thought of as opposing arms extending to either side of the rear bar, is provided with one or more openings 112, for example so that fastening means (shown as screws S) may be used to temporarily and removably secure the tool to one or more wall joists W. The forward edge 114 of the top plate 108 is biased across its thickness, and along its length, at the same angle at which the front bar 102 projects, such that the upper surface 116 of the front bar has an edge 118 in common with the upper surface 120 of the top plate 106. Finally, the lower end of the rear bar 104 is shown to include a U-shaped brace member 122, which consists primarily of a pair of parallel arms 124 that extend rearwardly from a base plate 126 that is coupled to the rear side of bar 104. As shown, parallel arms 124 are spaced from each other by a distance sufficient to provide a clearance fit for a wall joist W.

Thus, in the first embodiment 100, the top plate 108 of the crossbar 106 provides the support platform 16 of the positioning tool 10, with the upper surface 122 of the top plate forming the upper surface 18 of the support platform adapted to receive and support the forward edge of a construction panel such as a drywall sheet. The upper surface 120 of the front bar 102 provides the ramp section 18 of the tool, and the stabilizing member 14 is collectively formed from the rear bar 102, the side plate 110, and the brace member 122. More specifically, the rear surface of the side plate 110 is positioned to abut a horizontal wall joist W, for example a top plate, and be temporarily secured thereto, and the brace member 122 engages the vertical wall joist W. As mentioned above, but although not shown in this view, ceiling joists are typically supported on the top plates, so the tool 100 is generally installed in a position such that the upper surface 122 of the top plate 108 is spaced from the ceiling joist sufficiently to accommodate the thickness of a construction panel. In embodiments that include a brace member, the tool is generally centered (or otherwise positioned) relative to a stud (vertical wall joist W) so that the arms of the brace member loosely engage either side of the stud, such as to provide additional restriction of lateral movement of the tool relative to the wall frame.

in prototype embodiments represented by the first illustrative embodiment 100 of positioning tool 10, ¾″ square tubing was used for the front and rear bars, with the rear bar having an overall length in the range of about 10″ to 18″, and the front bar having an overall length in the range of about 18 to 24″. The downwardly projecting tip of the front bar, in some of the prototype embodiments, was smoothed or radiuses on its upper corner (as shown in FIGS. 1 and 2), and/or was bent to curve further downward, to present a smoother surface to the drywall sheet engaging the bottom end of the bar. Additionally, the angle between the front and rear bars was in the range of about 45 to 55 degrees (resulting in the angle formed between the upper surface of the ramp section and the upper surface of the support platform being in the range of about 35 to 45 degrees). A length of 1″×1″ angle steel in the range of about 6″ to 10″ was used for the crossbar. However, some variants were not provided with a crossbar, instead having openings through the rear bar for securement to a wall stud, and having support platform only as wide as one or both of the front and rear bars. Also, some variants were not provided with a brace member; in some applications, such as those in which multiple positioning tools were installed in parallel on a wall frame, to provide multiple points of support for a drywall sheet placed thereon, the brace member was found not to be as helpful to restrict lateral movement of the individual tools as in applications in which only one positioning tool was used.

In FIGS. 3 and 4, the second illustrative embodiment 200 of positioning tool 10 is also shown to be constructed from two bars 202, 204 of square steel tubing, coupled at the ends thereof to form an apex, but with the front bar 202 projecting forward at an obtuse angle relative to the rear bar 204, which is shown in this embodiment to be horizontally oriented. The upper surface 206 of the front bar has an upper edge 208 in common with the upper surface 210 of the rear bar 204. A brace 212, shown as an elongate bar of angle steel, is coupled at its proximal end to the distal end of the rear bar 204 and extends generally rearwardly therefrom along a longitudinal axis parallel to that of the rear bar. Brace 212 consists of a side plate 214, the lower portion of which, at the forward end thereof, is coupled to a side surface of the rear bar 204, and a top plate 216, which is spaced upward from the upper surface 210 of the ear bar by a distance sufficient to accommodate the thickness of a forward edge of a construction panel. Top plate 216 is provided with one or more openings 218, for example so that fastening means (shown as screws S) may be used to temporarily secure the tool to one or more ceiling joists C, for example through a construction panel P installed thereto,

In the second embodiment 200, the rear bar 204 provides the support platform 16 of the positioning tool 10, with the upper surface 210 thereof forming the upper surface 24 of the support platform adapted to receive and support the forward edge of a construction panel such as a drywall sheet. The front bar 202 provides the ramp member 12, with the upper surface 206 of the front bar 202 providing the ramp section 18 of the tool. The stabilizing member 14 is in the form of the brace 212.

In prototype embodiments represented by the second illustrative embodiment 200 of positioning tool 10, ¾″ square tubing was used for the front and rear bars, with the rear bar having an overall length in the range of about 2″ to 6″, and the front bar having an overall length in the range of about 18″ to 24″. As with embodiment 100, the downwardly projecting tip of the front bar, in some of the prototype embodiments, was smoothed or radiused on the upper corner (as shown in FIGS. 3 and 4), and/or was bent to curve further downward, and the angle between the front and rear bars was in the range of about 135 to 145 degrees (resulting in the angle formed between the upper surface of the ramp section and the upper surface of the support platform being in the range of about 35 to 45 degrees). A length of 1″×1″ angle steel in the range of about 10″ to 14″ was used for the crossbar, with the length of the front end coupled to the side surface of the rear bar being in the range of about 1″ to 4″. The clearance between the upper surface of the rear bar and the top plate was between about ¼″ to ¾″. In some variants, the support platform was laterally extended by means of an additional crossbar configured to extend to either side of the rear bar.

A first, non-exclusive, illustrative embodiment of a construction panel support tool 40 is shown in FIG. 5 at 300, and a second, non-exclusive, illustrative embodiment is shown in FIGS. 6-9 at 400. Briefly, both embodiments of support tool 40 are adapted to temporarily support an edge, edge portion, or other portion of a construction panel P in a desired position, such as adjacent to an installation site. In particular, support tool 300 is adapted to movably mount to a ceiling joist C and be selectively moved into place to support the lower surface of a sheet of drywall in position substantially adjacent to one or more ceiling joists to which the sheet is to be installed. Support tool 400, on the other hand, may be immovably secured to a ceiling joist, but includes a movable support member that may be selectively moved into place to support a sheet of drywall in a similar manner, The structural differences between the two illustrative embodiments are primarily those that allow the first embodiment to be movably mounted to a ceiling joist and moved, as a unit, into place, whereas the second is secured in place but includes moveable components. Thus each may have particular utility in different construction circumstances, as will become clear from the following description.

In general and somewhat functional terms, each of the support tool embodiments includes a suspension frame 42 adapted to mount the tool on a ceiling joist C, and a support member 44 coupled thereto and disposed to extend away therefrom, such as in a plane parallel to that of the bottom surface of the ceiling joist C to which the suspension frame 42 is mounted.

More specifically, as can be seen in FIG. 5, suspension frame 42 of support tool 300 is shown to be formed from elongate top and bottom guide members 302, 304 coupled to each other by means of struts 306. In particular, top guide member 302 forms a channel adapted to provide at least a clearance fit with the top edge of a ceiling joist C, with the channel defined by parallel sidewalls 308 extending downward from a top wall 310. Bottom guide member 304 includes a sidewall 312 and a bottom wall 314 adapted, respectively, to engage one side and the bottom edge of the ceiling joist C. This configuration allows the entire frame 42 to be suspended from a ceiling joist by “hanging” the top guide member over the top edge at a slight angle, then engaging the bottom wall 314 with the bottom edge of the joist. The struts maintain a predetermined spaced relation between the top and bottom guide members. Optionally, the guide members may be adjustably coupled, such as to accommodate ceiling joists of different widths (for example, 2×8s, 2×6s, and 2×4s are all lumber sizes that are commonly used for ceiling joists). In support tool 300, the adjustability is provided by means of openings along struts 306 through which bolts 316, which protrude from sidewall 312, may extend and be fastened by means of nuts 318.

The support member 44 of support tool 300 is shown to be formed from an elongate bar 320 of square steel tubing that cantilevers in a direction parallel to a longitudinal axis of the support frame, in a plane substantially parallel to, and spaced below, the bottom surface of the ceiling joist, In particular, the spacing is sufficient to accommodate the thickness of a construction panel. Bar 320 is coupled to the suspension frame by means of a pair of bolts 322, which protrude downward from bottom wall 314, and which are fastened by nuts 324. Although not required to all embodiments, this coupling is also shown in support tool 300 to be adjustable, such as to allow a user to adjust the clearance between the top surface of the bar 320 and the bottom surface of the ceiling joist C. The clearance may be determined by user preference, thickness of the particular construction panel with which the support tool is being used, and so forth, but is generally a value greater than the thickness, but less than about twice the thickness, of a construction panel.

In prototype embodiments represented by embodiment 300 of support tool 40, a length of 1″ square tubing having an overall length in the range of about 24″ to 30″ was used for the elongate support bar. The top and bottom guide members both had an overall length in the range of about 6″ to 10″, which was suitable to prevent the suspension frame from rocking or tipping on the ceiling joist when the weight of a sheet of drywall is supported b the support bar.

In some prototypes, instead of bolts, one or both struts extend beyond the bottom guide member to either adjustably (by means of additional openings) or non-adjustably (such as by welding) couple with the support bar, In one variant, the support bar is mounted for a limited range of pivotal movement in a vertical plane on one strut, and a biasing means in the form of a tension spring positioned to bias the distal end of the bar upward, for example to urge the end of the bar against a sheet of drywall supported by the support tool.

In FIGS. 6-9, the second illustrative embodiment 400 of support tool 40 shown to include a suspension frame 42 of a different configuration as compared with the first embodiment 300. Suspension frame 42 of support tool 400 includes a mounting member, designated generally at 46, adapted to mount the tool to (or on) a ceding joist, such as adjacent a panel installation site, and a guide member, designated generally at 48, coupled thereto. Guide member 48 movably supports the elongate support member, which may be moved relative to the guide member between a deployed position and a standby position. In this context, the deployed position is a position in which the distal portion of the support member extends beneath the panel installation site, and may thereby support a panel in position for installation. A standby position refers to a position that is nota deployed position.

As perhaps best shown in FIGS. 6 and 7, suspension frame 42 of support tool 400 is shown to be formed from a generally flat mounting plate 402, from a middle portion of which two opposing side plates 404 extend downward. Although not required to all embodiments, mounting plate 402 includes flanges 406 that extend longitudinally past the edges of side plates 404. The mounting plate 402 is provided with one or more openings 408, for example so that fastening means (shown as screws S) may be used to temporarily and removably secure the tool to a ceiling joist C, either directly (as shown), or through a construction panel that has been installed thereto. In the second illustrated embodiment, mounting plate 402 thus functions as the mounting member 46.

Guide member 48 is shown in the form of a short length 410 of square steel tubing, also referred to herein as a sleeve, or sleeve portion. Guide member 48 in this embodiment is movably coupled to the mounting member in a pivotable manner: the top surface of sleeve 410 is shown to include a round tube 412 extending across its width, in which a pivot pin 414, which is supported across side plates 404, is received.

Support member 44 of support tool 400 is shown to be formed from an elongate bar 420 of square steel tubing that is movably supported on the guide member; more specifically, in support tool 400, elongate bar 420 is slidably received through the interior channel defined by sleeve 410 for translational movement along its long axis relative to the sleeve 410 between deployed and standby positions. In the illustrated embodiment, bar 420 cantilevers to either side of sleeve 410 in a direction parallel to a longitudinal axis of the suspension frame, in a plane substantially parallel to, and spaced below, the bottom surface of the ceiling joist,

Although not required to all embodiments, support tool 400 is also shown to include a handle 422 operatively attached to the support member 44, such as to assist a user in sliding the bar into and out of a desired position Handle 422 is shown to be in the form of a short bar of square steel tubing that projects downward from the proximal end of the bar 420,

Also, although not required to all embodiments, support tool 400 is also shown to include a locking feature in the form of a thumbscrew assembly 424, shown as a threaded thumbscrew 426 and a knob 428. Thumbscrew assembly 424, or more specifically thumbscrew 426, is threadably received in a vertical orientation through the distal portion of the bar 420. As shown in FIGS. 7 and 8, thumbscrew assembly 424 is selectively engageable to retain (or lock) the support member in a desired position relative to the guide member. More particularly, the distal end of thumbscrew 426, which may be thought of as a locking surface, is configured to be urged, such as by turning the knob, against a corresponding target surface to thereby form a friction lock. The target surface may be any desired surface, but to avoid damage to comparatively soft surfaces such as that of the joist C (or panel P) to which the tool is mounted, the mounting plate 402, or more particularly one of the flanges 406 thereof, may provide a suitable target surface against which the locking surface of the thumbscrew may be urged. As such, FIG. 7 shows the support member 44 being slid Into a deployed position, such that the distal end of the bar 420 extends beneath a panel P and the panel installation site to which it is to installed, and FIG. 8 shows the locking member being engaged, that is, the locking surface of the thumbscrew being urged against a flange 406, to retain the support member in the deployed position.

In the illustrated embodiment, thumbscrew assembly 424 in support tool 400, in addition to its function as a locking member, also functions as a biasing member that is selectively engageable to bias the distal portion of the support member toward the panel installation site, which in the illustrated embodiment is the plane of the ceiling joist to which the tool is mounted, As shown in FIG. 9, the pivotal coupling of the guide member with the mounting member allows the support member to function as a lever with the pivot pin 414 as the fulcrum, such that further tightening of the thumbscrew assembly 424 against the target surface draws the proximal end of the bar 420 toward the knob 428, correspondingly biasing the distal portion of the bar 420 upward. The biasing feature of the support tool may facilitate installation of a panel P to an installation site by allowing a user to use the tool to hold the panel P closer to, or even directly against, the joists to which the panel is to be installed.

In prototype embodiments represented by embodiment 400 of support tool 40, a length of ¾″ square tubing having an overall length in the range of about 30″ to 36″ was used for the elongate support bar. The sleeve portion was formed from a short length (of about 3″ to 5″) of 1″ square tubing. The mounting plate was formed from a flat 1″ wide bar of steel plate in the range of about 4″ to 8″, and the side plates were formed from similar bars of steel plate having lengths in the range of about 2″ to 6″. The handle was formed from a length of ¾″ square steel tubing having a length of about 6″ and affixed to the distal end of the elongate bar at an angle.

FIGS. 10-13 show components of a construction panel support system 50 in use to position and temporarily support multiple construction panels P (shown as sheets of drywall), relative to adjacent installation sites on a ceiling joist C. In general, system 50 includes one or more construction panel positioning tools 10 (such as tool(s) 100, as shown in FIGS. 1-2, and/or tool(s) 200, as shown in FIGS. 3-4, and so forth), and one or more construction panel support tools 40 (such as tool(s) 300, as shown in FIG. 5, and/or tool(s) 400, as shown in FIGS. 6-9). The structural components (i.e., joists W, C, and the drywall sheets P) and tools are not necessarily shown to scale, but rather are presented somewhat schematically for the sake of illustration.

In FIG. 10, a positioning tool 10 according to the first illustrated embodiment 100 is shown to be secured to a wall joist W such that the upper surface 24 of the support platform 16 is spaced from an adjacent ceiling joist C by a distance sufficient to accommodate a construction panel P. Construction panel P is shown with its forward edge placed on the upper surface 20 of the ramp section 18, and is guided up the ramp section in the direction shown by the arrow, such as if a worker holding the opposite edge pushes the panel along the ramp section. Although only one positioning tool 10 is shown in FIG. 10, two or more positioning tools may be deployed in parallel along a wall frame, such as to provide greater stability and support through the use of multiple, parallel ramp sections.

In FIG. 11, the forward edge of the construction panel P has been guided to the upper surface of the support platform, and is supported in position to be installed. The middle section of the construction panel P may then he pivoted upward and away from the ramp section, as shown by the arrow, such as by a worker lifting the opposite edge toward the ceiling.

In FIG. 12, a support tool 40 according to the illustrated embodiment 300 is shown to be movably suspended from ceiling joist C, and is moved into place so that the support member 44 engages the bottom surface of the construction panel P. In general, the support tool 40 engages the ceiling joist from which it is suspended loosely enough to be moved easily along the length thereof, for example so that a worker supporting the panel with one hand against the ceiling joists may reach back with the other hand to pull or otherwise slide the tool 40 into place. In a system in which a support tool according to the illustrated embodiment 400 is used, the tool would be secured to ceiling joist C, and a worker would slide the support member into a deployed position, such as by reaching back to use the handle, and then locking the support member in place by means of the thumbscrew assembly, such as shown in FIGS. 7-8, Of course, as shown in FIG. 9, the thumbscrew assembly may optionally be used to urge the panel P closer toward, or even directly up against, joists C. Again, although only one support tool 40 is shown in FIG. 12, two or more support tools may be deployed, for example to provide multiple points of support. The construction panel P is now in place relative to the installation site, and may be installed according to conventional methods, after which the positioning tool(s) 10 may be removed and the support tool(s) 40 may be moved from a supporting position,

In FIG. 13, a positioning tool 10 according to the second illustrative embodiment 200 is shown to be secured to ceiling joist C through construction panel P. Again, more than one positioning tool may be used, such as to provide multiple, parallel ramp sections. Also, the support tool has been moved away from the wall sufficiently to allow a second construction panel P to be raised and supported into positron relative to an installation site adjacent to the installed construction panel, Continuing in this manner, a solo worker may sequentially install multiple construction panels to the entire ceiling frame.

Several configurational variations may be made to the illustrative embodiments that are considered to be within the scope of the invention. For example, although the positioning tools 10 are shown to be of rigid construction, other embodiments may employ hinged, adjustable connections, such as a selectively pivotable coupling between the stabilizing member and the ramp member, so that a single unit may be employed for installation sites that are adjacent to walls as well as those that are not adjacent to walls, for example by moving the stabilizing member between vertical and horizontal orientations. Further, although the range of angles formed between the ramp section and a horizontal plane in the prototype embodiments is about 35 to 45 degrees, an angle anywhere in the range of about 20 to 60 degrees, or beyond, would have utility in certain applications. Moreover, the inclusion of an adjustable-angle coupling may provide a positioning tool capable of providing such a range. Optionally, positioning tool components forming the ramp member and/or stabilizing member may be of adjustable length, such as by employing a telescoping configuration, so that the positioning tool may be used in a greater number of applications. For example, ceiling heights in many installations may vary quite a bit, and a positioning tool with a ramp member of adjustable length may allow the vertical distance that a construction panel must be lifted in order to place the forward edge onto a ramp section to be kept minimal. Further, some embodiments of the positioning tools may include additional components, such as braces or supporting struts, as might suitable for a heavier-duty application, and/or multiple iterations of a particular component, such as parallel ramp members, multiple stabilizing members, and so forth; whereas others may include fewer components, such as indicated above, in which some embodiments of a positioning tool does not include a support brace. In some positioning tools, the stabilizing member may instead or additionally couple to the ramp section, and/or may be configured to engage one or more structural components of a building structure in a different manner than as shown.

Moreover, as shown, the support tools 40 may include a suspension frame that either remains in place on a ceiling joist (such as shown in embodiment 400) or is slidably mounted thereon (such as shown in embodiment 300). Either configuration may be provided with a handle, such as shown on illustrated embodiment 400, or more than one handle, which may be disposed other than as shown, to facilitate movement of either the suspension frame or the support arm, as appropriate to the configuration. Further, either configuration may be provided with a support member that is rigid relative to the suspension frame, such as in illustrated embodiment 300, or movable relative to the suspension frame, such as provided by the movable coupling between the guide member and the mounting member shown on illustrated embodiment 400. As shown in embodiment 400, the movable coupling may allow pivotable movement of the guide member in a vertical plane, but other embodiments may instead (or additionally) provide pivotable movement in a horizontal plane, such as to allow a the guide member and/or the support arm received in the guide member to be horizontally swung into a desired position. Further, the support member of illustrated embodiment 400 is shown to be slidably mounted for translational movement in the long axis of the support member, but other manners of mounting are possible, such as a pivotable mount. Either configuration may be provided with a locking feature such as that provided in the second embodiment, or otherwise, in any suitable form. Further, such as to allow the locking surface of the thumbscrew assembly to be engaged with the mounting plate in more positions of the support member, the support tool may be provided with several locking members, or a movable locking member (such as one that may be threaded through the support member in a range of positions). Although embodiment 400 features a thumbscrew assemble that functions as both a locking member and a biasing member, other embodiments may include separate components to provide locking and/or features, or several components that operate together to provide either or both features. A locking surface of a locking member may take any configuration, such as featuring a flat plate, which may be more suitable to engage a target surface other than the surface of a mounting plate.

Although the present invention has been shown and described with reference to the foregoing operational principles and Illustrated examples and embodiments, it will be apparent to those skilled in the art that various changes in form arid detail may be made without departing from the spirit and scope of the invention. The present invention is intended to embrace all such alternatives, modifications and variances that fall within the scope of the appended claims.

Claims

1. A construction panel support tool to support a construction panel relative to a panel installation site, the support tool comprising:

a suspension frame that includes a mounting member adapted to mount the tool to a ceiling joist adjacent a panel installation site, and a guide member coupled to the mounting member;

an elongate support member movably supported on h guide member and configured, when the tool is mounted on a ceiling joist, to be movable relative to the guide member between a deployed position in which the distal portion of the support member extends beneath the panel installation site and a standby position in which it does not.

2. The panel support tool of claim 1, wherein the mounting member includes a mounting plate adapted to be secured to a surface of the ceiling joist.

3. The panel support tool of claim 1, further including a locking member selectively engageable to retain the support member in a desired position relative to the guide member.

4. The panel support tool of claim 3, wherein the locking member is disposed on the proximal portion of the support member.

5. The panel support tool of claim 4, wherein the locking member is adapted to selectively engage the mounting member when the support member is in a deployed position.

6. The panel support tool of claim 3, wherein the locking member includes a thumbscrew threaded vertically through the distal portion of the support member, with the distal end thereof having a locking surface configured to be urged against a corresponding target surface to thereby form a lock.

7. The panel support tool of claim 6, wherein when the lock member is not engaged, the thumb screw is movable along the length of the distal portion of the support member.

8. The panel support tool of claim 3, wherein the guide member is pivotably mounted to the mounting member to provide a range of pivotal movement of the guide member about a pivot axis that is perpendicular to a long axis of the support member and parallel to the plane of the bottom surface of the ceiling joist.

9. The panel support tool of claim 8, further including a biasing member selectively engageable to bias the distal portion of the support member toward the plane of the ceiling joist to which the tool is mounted.

10. The panel support tool of claim 1, wherein the support member is coupled to the guide member to extend, when the tool is mounted on a ceiling joist, in a plane substantially parallel to, and spaced beneath, that of the bottom surface of the ceiling joist.

11. The panel support tool of claim 10, wherein the guide member includes a sleeve portion that defines a channel through which the support member is slidably received, such that the support member is configured for translational movement relative to the sleeve portion between the deployed and standby positions.

12. The panel support tool of claim 11, wherein the sleeve portion is rigidly mounted to the mounting member.

13. The panel support tool of claim 11, wherein the sleeve portion is pivotably mounted to the mounting member to provide a range of pivotal movement of the sleeve portion, and the support member slidably received therethrough, about a pivot axis that is perpendicular to a long axis of the support member and parallel to the plane of the bottom surface of the ceiling joist.

14. The panel support tool of claim 13, further including a biasing member selectively engageable to bias the distal portion of the support member toward the plane of the bottom surface of the ceiling joist to which the tool is mounted.

15. The panel support tool of claim 1, further including a handle operatively attached to the support member.

16. The panel support tool of claim 15, wherein the handle is disposed on the proximal portion of the support member.

17. A construction panel support tool to support a construction panel relative to a panel installation site, the support tool comprising:

a suspension frame having a mounting plate adapted to be secured to a ceiling joist adjacent the panel installation site;

a guide member pivotably coupled to the suspension frame;

an elongate support member slidably mounted to the guide member and extending, when the tool is mounted on a ceiling joist, in a plane substantially parallel to, and spaced beneath, that of the bottom surface of the ceiling joist;

wherein, when the tool is mounted on a ceiling joist, the support member is configured for movement along its long axis, relative to the guide member, between a deployed position in which the distal portion of the support member extends beneath the panel installation site and a standby position in which it does not; and

wherein, when the tool is mounted on a ceiling joist, the pivotal coupling of the guide member provides a range of pivotal movement of the support member in the vertical plane in which its long axis lies.

18. The panel support tool of claim 17, further including a thumbscrew disposed on a proximal portion of the support member and having a locking surface configured to be selectively engage and be urged against the mounting plate when the support member is in a deployed position, to thereby retain the support member in the deployed position.

19. The panel support tool of claim 18, wherein the thumbscrew is configured, when the locking surface is urged against the mounting plate, to correspondingly bias the distal portion of the support member toward the plane of a ceiling joist to which the tool is mounted.

20. A construction panel support system to position and temporarily support a construction panel relative to a panel installation site, the panel support system comprising:

one or more construction panel positioning tools, each positioning tool further including: a ramp member having a support platform at an upper end thereof configured to receive and support a portion of a construction panel and a ramp section adjacent the support platform and sharing a common edge therewith, the ramp section including a substantially planar upper surface configured to slidingly engage and guide a portion of a construction panel placed thereon toward the support platform; and a stabilizing member coupled to the ramp member, the stabilizing member being configured to engage a structural component of a building structure to support the ramp member in a predetermined position relative to the installation site; and

one or more construction panel support tools, each support tool further including: a suspension frame adapted to mount the support tool on a ceiling joist adjacent a panel installation site; and an elongate support member movably supported on the suspension frame and configured, when the tool is mounted on a ceiling joist, to be moved relative to the suspension frame member between a deployed position in which the distal portion of the support member extends beneath the panel installation site and a standby position in which it does not.