Wall Plumbing and Leveling Device

The innovations described herein relate to a device that plumbs and levels a framed wall, and, more particularly, to a device installed on a stud in a framed wall to plumb and level that particular stud with reference to all studs in the wall.

Stud walls are common in frame construction. Each stud-framed wall may include two or more studs typically installed vertically to form the frame of the wall. Ideally, each stud is installed vertically straight (also called plumb) and horizontally straight (also called level) with reference to all other studs in the frame of the wall, and adjacent walls are installed at a ninety degree angle to each other (also called square). A stud-framed wall that is plumb and level and square with other walls allows finishes to be properly installed on the wall.

A stud-framed wall may not be plumb, level, and/or square for several reasons. For example, poor installation can result in studs that are installed askew with respect to each other and/or with the floor, ceiling, or adjacent walls. Additionally, the manufacturing process can produce studs that are not “true.” A board that is “true” is a piece of lumber that is straight without deviation. Today, most pine timber is grown in a twenty-year period and is rushed through lumber mill production. This process causes modern lumber to include many defects, such as warping and/or unevenness in the cut edges or length. Even metal studs, which can be made with more uniform sizing, can be installed incorrectly, resulting in framed walls that are not plumb, level, and/or square.

If the studs in the stud-framed wall are not plumb and level with respect to each other, the finished wall will include defects in craftsmanship and appearance. For example, in the simplest construction, paneling is attached directly to the studs to create wall. The paneling will show flaws in the stud frame. If the studs are not plumb, then the paneling will be angled with respect to the floor. If the studs are not level with each other, then the paneling will have an uneven or wavy surface.

Other wall finishes also show the flaws in the stud-framed wall. For example, a tile wall may be difficult to install over an uneven stud-framed wall and/or will show the flaws of the stud frame. For a tile wall, a backer board is first installed to the stud-framed wall, and the tile is attached to the backer board with mortar. If the stud-framed wall is not plumb and level, then the backer board installed to the stud-framed wall also will not be plumb and level. Then, these flaws may be exaggerated in the finished tile surface.

Similarly, flaws in the stud-framed wall show in other wall finishes. For example, dry wall attached to a stud-framed wall that is not plumb and level will show, and in some cases, exaggerate, the flaws in the stud-framed wall. Additionally, finishes on the dry wall, such as paint, stain, wallpaper, or other finish, will further show and/or exaggerate the flaws in the stud-framed wall.

Conventional methods to correct the flaws in stud-framed wall are not precise and cause additional issues that must be addressed during construction. One conventional method to correct plumb and/or level in a stud-framed wall is to attach an additional stud on the side of each stud that is not plumb and level. This process doubles the material cost and increases the labor cost for each stud that is corrected. Additionally, adding another stud on the side interferes with the work of other trades. For example, if other trades have already installed pipes, wires, or other materials through the stud-framed wall, then the additional stud may damage those existing items. Or, the additional stud must be notched around the existing items, which further increases the labor cost to correct the flaws in the original framing of the wall.

For walls that will be finished with tile, another conventional method to correct flaws in stud-framed walls involves placing mortar on the studs behind the backer board for the tile. The studs are covered with mortar and the backer board is placed on the mortar. Then, the backer board is screwed to the studs gently, which compresses the mortar. The screws are tightened until the backer board compresses the mortar and results in the backer board being plumb and level. This process is time-consuming and difficult. If any screw is tightened too much, then the error cannot be corrected, or the backer board and mortar must be removed to restart the process. Additionally, the installer must wait for the mortar to set before tile installation can begin.

This description relates to a device, system, and method to correct material and installation defects in stud-framed walls by installing framing devices over an edge of the studs in the wall. The front face of each framing device is aligned vertically and horizontally with each other framing device while securing the framing devices to the studs on the wall. Additionally, the framing devices on one wall can be aligned square with framing devices on an adjacent wall.

In some aspects, the techniques described herein relate to a plumbing and leveling device as described herein.

In some aspects, the techniques described herein relate to a method to plumb and/or level a stud in a wall as described herein.

In some aspects, the techniques described herein relate to a method to plumb and level multiple studs in a wall as described herein.

In some aspects, the techniques described herein relate to a device to plumb and level construction materials, including: a body including a U-shaped profile including an elongated front face having a first edge and a second edge, a first side face, and a second side face, the first side face being disposed along the first edge of the front face, and the second side face being disposed along the second edge of the front face.

In some aspects, the techniques described herein relate to a device, wherein the first side face is disposed orthogonally to the front face along the first edge of the front face, and the second side face being disposed orthogonally to the front face along the second edge of the front face.

In some aspects, the techniques described herein relate to a device, the body further including a first flange face comprising a first edge and a second edge; and a second flange face comprising a first edge and a second edge, wherein the first side face is disposed along the first edge of the front face by the first edge of the first flange face being disposed along and extending angled from an edge of the first side face and the second edge of the first flange face being disposed along and extending angled from the first edge of the front face, and wherein the second side face is disposed along the second edge of the front face by the first edge of the second flange face being disposed along and extending angled from an edge of the second side face and the second edge of the second flange face being disposed along and extending angled from the second edge of the front face.

In some aspects, the techniques described herein relate to a device, wherein a width of the front face is wider than a distance between an outside of the first side face and an outside of the second side face.

In some aspects, the techniques described herein relate to a device, wherein a distance between the first side face and the second side face corresponds to a thickness of a stud to which the device is configured to attach.

In some aspects, the techniques described herein relate to a device, wherein a distance between the first side face and the second side face is larger than a thickness of a stud to which the device is configured to attach.

In some aspects, the techniques described herein relate to a device, wherein a depth of each of the first side face and the second side face extending away from the front face corresponds to a width of a stud to which the device is configured to attach.

In some aspects, the techniques described herein relate to a device, wherein a depth of each of the first side face and the second side face extending away from the front face is less than one-half of a width of a stud to which the device is configured to attach.

In some aspects, the techniques described herein relate to a device, wherein a depth of each of the first side face and the second side face extending away from the front face is more than one-half of a width of a stud to which the device is configured to attach.

In some aspects, the techniques described herein relate to a device, wherein a depth of each of the first side face and the second side face extending away from the front face is equal to one-half of a width of a stud to which the device is configured to attach.

In some aspects, the techniques described herein relate to a device, wherein each of the first side face and the second side face include a plurality of holes therein.

In some aspects, the techniques described herein relate to a device, wherein each of the plurality of holes in the first and second side faces is sized to accommodate a fastener to attach the device to a stud.

In some aspects, the techniques described herein relate to a device to plumb and level construction materials, including: a body including a U-shaped profile including an elongated front face having a first edge and a second edge, a first side face, and a second side face, the first side face being disposed orthogonally to the front face and along the first edge of the front face, and the second side face being disposed orthogonally to the front face and along the second edge of the front face, a distance between the first side face and the second side face corresponding to a thickness of a stud to which the device is configured to attach, an interior depth of each of the first side face and the second side face extending away from the front face is less than one-half of a width of a stud to which the device is configured to attach, and each of the first side face and the second side face including a plurality of holes therein that are sized to accommodate a fastener to attach the device to a stud.

In some aspects, the techniques described herein relate to a device to plumb and level construction materials, including: a body including: an elongated front face having a first edge and a second edge; and a first side face disposed along the first edge of the front face.

In some aspects, the techniques described herein relate to a device, wherein the device includes an L-shaped profile.

In some aspects, the techniques described herein relate to a device, wherein the first side face is disposed orthogonally to the front face along the first edge of the front face.

In some aspects, the techniques described herein relate to a device, the body further comprising: a first flange face comprising a first edge and a second edge; and wherein the first side face is disposed along the first edge of the front face by the first edge of the first flange face being disposed along and extending angled from an edge of the first side face and the second edge of the first flange face being disposed along and extending angled from the first edge of the front face.

In some aspects, the techniques described herein relate to a device, further including a second side face disposed orthogonally to the front face and along the second edge of the front face, wherein the device includes a U-shaped profile.

In some aspects, the techniques described herein relate to a device, wherein a width of the front face corresponds to a thickness of a stud to which the device is configured to attach.

In some aspects, the techniques described herein relate to a device, wherein a width of the front face is less than a thickness of a stud to which the device is configured to attach.

In some aspects, the techniques described herein relate to a device, wherein a depth of the first side face extending away from the front face corresponds to a width of a stud to which the device is configured to attach.

In some aspects, the techniques described herein relate to a device, wherein a depth of the first side face extending away from the front face is less than one-half of a width of a stud to which the device is configured to attach.

In some aspects, the techniques described herein relate to a device, wherein the first side face includes a plurality of holes therein, each of the plurality of holes being sized to accommodate a fastener to attach the device to a stud.

In some aspects, the techniques described herein relate to a method to plumb and level studs in a stud-framed wall, including: providing a wall including a first stud and a second stud in a spaced-apart fashion, each of the first and second studs including a defect in manufacturing or installation causing the first and second studs to be out of vertical plumb and horizontal level with each other; providing a first device and a second device to plumb and level construction materials, each device including a body including a U-shaped profile including an elongated front face having a first edge and a second edge, a first side face, and a second side face, the first side face being disposed along the first edge of the front face, and the second side face being disposed along the second edge of the front face; positioning the first device over an edge of the first stud such that the first and second side faces of the first device overlap a width of the first stud and such that the front face of the first device is vertically plumb, and attaching the first device to the first stud in this position; and positioning the second device over an edge of the second stud such that the first and second side faces of the second device overlap a width of the second stud and such that the front face of the second device is vertically plumb and horizontally level the front face of the first device, and attaching the second device to the second stud in this position. In some aspects, the techniques described herein relate to a method, the body of each device further comprising: a first flange face comprising a first edge and a second edge; and a second flange face comprising a first edge and a second edge, wherein the first side face is disposed along the first edge of the front face by the first edge of the first flange face being disposed along and extending angled from an edge of the first side face and the second edge of the first flange face being disposed along and extending angled from the first edge of the front face, and wherein the second side face is disposed along the second edge of the front face by the first edge of the second flange face being disposed along and extending angled from an edge of the second side face and the second edge of the second flange face being disposed along and extending angled from the second edge of the front face.

In some aspects, the techniques described herein relate to a method, wherein a distance between the first side face and the second side face of each of the first and second devices corresponds to a thickness of the respective first and second studs to which the device is configured to attach.

In some aspects, the techniques described herein relate to a method, wherein a depth of each of the first side face and the second side face of each of the first and second devices extending away from the front face is less than one-half of a width of the respective first and second studs to which the corresponding device is configured to attach.

In some aspects, the techniques described herein relate to a method, wherein each of the first side face and the second side face of each of the first and second devices include a plurality of holes therein that are each sized to accommodate a fastener to attach the respective first and second devices to the corresponding first and second studs.

These and other aspects, objects, features, and advantages of the invention will become apparent to those having ordinary skill in the art upon consideration of the following detailed description of illustrated examples.

The innovations described herein relate to a framing device that plumbs and levels a stud-framed wall. In a stud-framed wall, the framing device is placed on one or more of the studs to create a wall face that is plumb and level across all studs in the wall. Then, the wall finishes are attached to the wall face by attaching to the front face of each framing device (or, in some cases, also to the edge of the studs that were already plumb and level).

The framing device is designed to cap existing walls, in new or old construction, which allows walls to be made plumb, level, and square. In fields such as drywall, trim, tile, and others, walls that are not plumb, level, and square cause additional material and labor costs to correct. The framing device described herein corrects defects in stud-framed walls, and can decrease the material cost, labor cost, and time involved with correcting such defects compared to conventional methods.

With reference to(comprising), wall plumbing and leveling devices will be described.is a perspective view of a wall plumbing and leveling device.is an end view of the wall plumbing and leveling devicedisposed around a wall stud.

As shown in, the wall plumbing and leveling devicecomprises a channel-shaped bodyincluding a front faceand two side faces,disposed along edges of the front faceto form the channel-shaped body. The channel-shaped bodyof the wall plumbing and leveling devicecomprises a “U” shape. Each side face,includes multiple holestherein. The holesallow insertion of fasteners, such as nails, screws, self-tapping screws, or other suitable fastener, to attach the wall plumbing and leveling deviceto a wall stud().

As shown in, the wall plumbing and leveling devicefits over an edgeof a stud. For a stud having a width W, the wall plumbing and leveling devicefits over a portion x of the width W of the stud, leaving a portion y of the width W of the stud uncovered. The widths of the portions x and y, and therefore the corresponding depths of the side faces,of the wall plumbing and leveling devicecan be designed to provide desired characteristics. For example, if the depth of the wall plumbing and leveling devicecovers a larger portion x of the width W of the stud, the wall plumbing and leveling devicemay be more securely attached to the stud. However, the wall plumbing and leveling deviceonly needs to cover a portion x of the width W of the studto provide sufficient structural strength for the wall finishes and to allow enough room for fasteners to attach the wall plumbing and leveling deviceto the stud. Additionally, the wall plumbing and leveling devicecan leave a sufficiently large portion y of the width W of the studuncovered to allow other trades to utilize the portion y for installation, or such that the wall plumbing and leveling devicedoes not interfere with materials already installed in the stud. For example, the portion y of the studcan be utilized for running pipes, wire, ducts, or other materials, and the wall plumbing and leveling devicewill not interfere with these materials in the stud. In one design, the depth of the side faces,of the wall plumbing and leveling deviceare less than half the width W of the stud. In this manner, other trades may utilize the middle of the studto run their materials. For example, for a typical 2×4 stud, the width W is 3.5 inches, and the depth of the side faces,can be 1.25 inches, which corresponds to the portion x of the width W of the stud. In this case, the wall plumbing and leveling devicewill not extend over the middle of the width W of the stud. In other designs, the depth of the side faces,of the wall plumbing and leveling devicecan equal to or be more than half the width W of the stud, as desired.

A width of the front faceof the wall plumbing and leveling devicecorresponds to a thickness T of the stud. For example, for a typical 2×4 stud, the thickness T is 1.5 inches, and the interior width of the front faceis sized to separate the side faces,by at least 1.5 inches. The interior width of the front facealso can be sized slightly larger than the thickness T of the stud(for example, 1.6 inches for a typical 2×4 stud) to allow easier installation of the wall plumbing and leveling deviceover the edgeof the stud. The interior width of the front facealso can be increased to accommodate studs having a larger thickness or to accommodate two or more studs positioned side by side, for example, in a doorway frame, window frame, or other framing technique.

In this manner, various profiles of the wall plumbing and leveling devicedevice can be manufactured for different applications. For example, for a typical 2×4 stud wall, the wall plumbing and leveling device can be manufactured with an interior width of the front faceof 1.6 inches and a depth of the side faces,of 1.25 inches. These profiles can be manufactured in various lengths corresponding to standard stud lengths (or wall heights), such as 8, 10, or 12 feet or any other desired length. The dimensions of the profiles of the wall plumbing and leveling devicecan be modified for different applications. The design discussed previously also fits any size stud having the standard 2× profile, for example, 2×6, 2×8, 2×10, 2×12, etc.

The holesin the wall plumbing and leveling deviceallow fasteners, such as screws, nails, bolts, or other suitable fastener, to be inserted therein to secure the wall plumbing and leveling deviceto the stud. The holes may not be utilized in cases where the fasteners can penetrate the side faces,, such as when using nails, screws, or self-tapping screws that penetrate the side faces,without damaging the side faces,

Other profiles of the wall plumbing and leveling device also can be utilized. For example, an L-shaped profile may be utilized as shown in.is an end view of an alternative L-shaped wall plumbing and leveling devicedisposed around the wall stud. As shown in, the L-shaped wall plumbing and leveling devicecomprises an L-shaped bodyincluding a front faceand a side face. The L-shaped wall plumbing and leveling deviceincludes all the features, and may be utilized in any manner, as described herein with reference to the wall plumbing and leveling device, except that the wall plumbing and leveling deviceincludes only a single side face. The wall plumbing and leveling devicereduces material cost and installation cost, while providing a plumb and level surface to which finishes can be attached. In this case, a width of the front faceof the wall plumbing and leveling deviceis not dependent on the thickness T of a studto which the wall plumbing and leveling deviceis attached. The width of the front faceof the wall plumbing and leveling devicecan be sized less than, more than, or equal to the thickness T of the studto which the wall plumbing and leveling deviceis attached. To reduce material cost and weight, the width of the front faceof the wall plumbing and leveling devicecan be less than the thickness T of the studto which the wall plumbing and leveling deviceis attached, and the front faceof the wall plumbing and leveling devicecan have a width sufficient to attach the wall finishes (for example, wide enough to hold a fastener used to attach the wall finishes to the wall plumbing and leveling device). To provide more structural support for the wall finishes or to allow a larger surface to which the wall finishes can be attached, the width of the front faceof the wall plumbing and leveling devicecan be sized equal to or more than the thickness T of the studto which the wall plumbing and leveling deviceis attached.

The wall plumbing and leveling device described herein can be adapted for any desired profile, for example, for use in doorways, windows, and corners. The width of the front facecan be increased or decreased to accommodate any desired width, for example, to cover door/window framing, multiple studs positioned side by side, headers (increased thickness because of combined studs, plywood, and/or other materials), or the face (width) of a stud. The depth of the side faces,can be increased or decreased as desired based on the corresponding stud, frame, header, or other item being corrected. Two wall plumbing and leveling devicescan be used on opposing sides of wider framing instead of forming a wall plumbing and leveling device having a very wide front face