Guiding device for assembling building panels

Abstract

The invention relates to a guiding device for assembling a building panel. A device guides first and second assembly components into a predetermined configuration, each assembly component including an opening. When the assembled components are aligned into a predetermined configuration, their openings align to define a cavity for receiving the stepped stud to secure the components together. The guide device includes: a stepped dowel member having a continuously decreasing dowel section; and a collar member that floats around the base of the stepped stud member. The tip of the stepped stud member may pass through the opening of the first assembly component and be inserted into the opening of the second assembly component, thereby pulling the components into a predetermined configuration. When the components are aligned into a predetermined configuration, the collar member engages the opening of the first assembled component and the stepped stud member engages the opening of the second assembled component. The guide device can be disengaged, thereby releasing the stud receiving cavity to receive a stepped stud for securing the assembly components together.

Description

[0001] This application is a divisional application of an application filed on June 22, 2020, with application number 202080046911.1, and invention name “Guiding device for assembling building panels”. CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of the filing date of U.S. Provisional Application Serial No. 62 / 865,488, filed on June 24, 2019, entitled “Guidance Apparatus For Assembly Of Construction Panels,” which is incorporated herein by reference as if fully set forth herein. field

[0003] The present invention relates to a device for guiding assembly components into a predetermined configuration suitable for a fastening mechanism to secure the constructed components together into a predetermined assembly configuration. The present invention also relates to a method of using a guiding device to align assembly components to receive a fastening mechanism to secure the components into their predetermined assembly configuration.

[0004] In particular, the invention relates to guiding prefabricated wall components into a predetermined configuration relative to floor components or ceiling components so that the components, when placed in the aligned configuration, form dowel-receiving cavities for receiving stepped dowels. Background of the Invention

[0005] In order to assemble a multi-component assembly, the individual components must be aligned to specific positions relative to the other components in order to allow a fastening mechanism to secure the components together in the desired assembled configuration of the multi-component assembly. This can be difficult, especially when the components are large or heavy, or when the components must be manipulated into a precise configuration. Assembly is problematic when the alignment position is not easily visible or detectable by the individuals assembling the components. Such assembly can be particularly difficult in situations where there is limited space to manipulate the components during assembly.

[0006] For example, a prefabricated multi-panel wall assembly may be assembled from a plurality of smaller wall panel components and subsequently secured to floor components and to ceiling components. Such components are typically large and heavy, and the fastening mechanisms used to join them typically require that the components be arranged with great precision to allow the fastening mechanisms to secure the components together. Typically, such components are prefabricated to include structures for engaging the fastening mechanisms, and these structures must be sufficiently aligned to receive the mechanisms that fasten them together.

[0007] The fastening mechanisms may be of much smaller relative size than the assembly structure, which may make them difficult to align together, especially where there is little room for alignment error. During the assembly process, the components themselves may prevent the assembler from aligning the components using his senses to determine whether the components are properly positioned.

[0008] There is a need for a mechanism for guiding two or more components into an assembled system. For example, there is a need for an apparatus for aligning prefabricated wall system components into a desired configuration that enables a fastening mechanism to engage and secure the components together. In particular, there is a need for a guiding mechanism that can be deployed to quickly and accurately align prefabricated components of such wall systems and other assembled systems together.

[0009] In particular, there is a need for a guide mechanism that can be quickly and easily removed from the assembly system after the wall system components have been aligned so that the components are aligned relative to each other in the assembled configuration. There is a need for a temporary guide device that can accurately align the components and then be removed without disturbing the position of the aligned components.

[0010] There is a particular need for a guide device that can be deployed to guide the assembled parts into an optimal configuration for fastening them together while the assembled parts are in transit. It would be useful to have a guide device that can be deployed before the assembled parts are in physical contact with each other, especially after one of the parts has been lifted and before it has been placed at its destination. At this point, relatively little force is required to precisely align the parts while the weight of the parts is supported by the transport equipment.

[0011] There is also a need for a device that can be used to temporarily manipulate the position of such large components, which can be used in conjunction with other equipment that has the capacity or size to complete the large component handling. There is a need for a transport device that can be brought into temporary engagement with a large assembly component, complete the positioning of the component, and then disengage from the assembly component without damaging, altering or changing the relative position of the components.

[0012] There is a need for a transport device that is portable and can be used in confined spaces, the transport device having a structure that enables the transport device to temporarily bear the weight of assembly components of greater relative size or weight. There is also a need for a transport device that is made of a minimum number of components, can be quickly and easily used and removed, can quickly and easily position assembly components, and then be removed from aligned components to facilitate engagement of fastening mechanisms.

[0013] What is needed is a method of using common building components or elements to achieve the alignment of assembly parts into a predetermined configuration, combining these assembly parts in a manner that creates a transport device for moving large or heavy assembly parts into a desired configuration to facilitate the engagement of fastening mechanisms that secure the parts into the assembled configuration. Brief description of the invention

[0014] One major aspect of the present invention relates to an apparatus or device for guiding individual components of an assembly system into alignment with other components of the assembly system so as to align the components to specific predetermined positions relative to each other, thereby allowing a fastening mechanism to secure the components together in a desired assembly configuration of a multi-component assembly.

[0015] One embodiment of the present invention relates to a device for guiding a first assembly component and a second assembly component into an assembled configuration, the guiding device comprising: i) a dowel member having: a base portion; a tip portion; and a plurality of dowel segments, each successive dowel segment having a cross-section that is smaller than the cross-section of a previous dowel segment; and ii) a collar member disposed around the base portion of the dowel member and slidably engaged therewith; such that the first assembly component includes a channel and the second assembly component includes a hole, such that when the first assembly component and the second assembly component are aligned in the assembled configuration, the channel and the hole define a cavity configured to receive a stepped dowel; and such that by engaging i) the collar member to the hole of the first assembly component and ii) the stepped dowel member to the hole of the second assembly component, the assembly components are positioned into a predetermined configuration.

[0016] Another aspect of the invention relates to a guide device comprising a flange having a cross-section that is greater than the cross-section of the collar member.

[0017] Another aspect of the invention relates to a guide device comprising a base portion of a dowel member including means for providing a grip for a hand tool.

[0018] Another aspect of the invention relates to a guide device comprising a metal material.

[0019] Further aspects relate to a guide device for aligning assembly components such that the assembly components define structure for engaging a fastening mechanism for securing the assembly components in an assembled configuration.

[0020] Some aspects relate to a guide device for aligning assembly components defining a dowel receiving cavity. Additional aspects relate to a guide device defining a cavity for receiving a stepped dowel.

[0021] One aspect relates to a guide device for assembling components of a wall system for aligning a wall panel or a wall panel assembly to a component associated with a floor or ceiling of the wall system.

[0022] Another general aspect of the present invention relates to a method of aligning components of an assembly system relative to one another into an aligned predetermined configuration using a guide device.

[0023] An embodiment of the present invention relates to a method for assembling a wall system, comprising: providing a wall panel having a hole on a top surface, the hole of the wall panel being used to engage a stepped dowel; providing a ceiling member having opposing elongated upper and lower longitudinal surfaces, and a dowel cavity extending through the longitudinal surfaces; positioning a guide member to engage the cavity of the ceiling member, the guide member having a plurality of dowel sections, each successive dowel section having a cross-section smaller than a cross-section of a previous dowel section; positioning the guide member to engage the hole of the wall panel, one end of the guide member engaging the cavity of the ceiling member, and the other end of the guide member engaging the hole of the wall panel; positioning the ceiling member and the wall panel in a predetermined orientation; removing the guide device; and inserting the stepped dowel into a dowel receiving cavity defined by the cavity of the aligned ceiling member and the hole of the wall panel, thereby connecting the aligned ceiling member to the aligned wall panel and assembling the wall system.

[0024] Another aspect of the invention relates to a method that includes applying an adhesive material to a dowel receiving cavity or a dowel such that the adhesive material is ultimately disposed in the dowel receiving cavity.

[0025] Another aspect of the invention relates to a method wherein the guide means comprises a collar member surrounding and slidingly engaging the dowel segment, the collar member having a cross-section that is larger than a cross-section of the dowel segment.

[0026] Another aspect of the invention relates to a method wherein the base portion of the guide device comprises means for providing a grip for the hand tool.

[0027] Yet another aspect of the present invention relates to a method wherein the guide member includes a collar member slidingly engaging the first dowel section, the collar member having a cross-section that is larger than a cross-section of the first dowel section.

[0028] Another embodiment of the present invention relates to a device for guiding a first assembly component and a second assembly component into a predetermined configuration, the guiding device comprising: i) a stepped dowel member having a plurality of dowel sections, each successive dowel section having a cross-section that is smaller than the cross-section of a previous dowel section; and ii) a collar member surrounding the first dowel section and slidably engaging the first dowel section; whereby each assembly component comprises a stepped opening, such that when the assembly components are positioned in an assembled configuration, the aligned stepped openings define a cavity for receiving a stepped dowel; and whereby the assembly components are positioned in an assembled configuration by the stepped dowel member passing through the stepped opening of the first assembly component and entering the stepped opening of the second assembly component, such that the collar member engages the stepped opening of the first assembly component and the stepped dowel member engages the stepped opening of the second assembly component.

[0029] Another aspect of the invention relates to a guide device having a stepped dowel member including a sensor. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1A and Figure 1B Side views of embodiments of an apparatus for guiding and aligning assembly components are shown with a movable collar member in different positions.

[0031] Figure 2 A cross-sectional side view showing a guide arrangement for aligning a ceiling component placed onto a wall panel.

[0032] Figure 3 A cross-sectional view of a stepped dowel fastening a ceiling member and a wall panel together is shown after a guide member has been used to align the ceiling member and the wall panel to define a dowel-receiving cavity and has been removed.

[0033] Before explaining the disclosed embodiments of the present invention in detail, it should be understood that the application of the present invention is not limited to the details of the specific arrangement shown, as the present invention is capable of other embodiments. Exemplary embodiments are shown in the figures of the accompanying drawings with reference. It is intended that the embodiments and drawings disclosed herein should be considered illustrative rather than restrictive. In addition, the terms used herein are for descriptive purposes only and not for limitation. Detailed Description

[0034] Although the present invention allows for many different forms of embodiments, some specific embodiments are shown in the drawings and will be described in detail herein, where it should be understood that the present disclosure is an example of the principles of the present invention. It is not intended to limit the present invention to these specific illustrative embodiments. The features disclosed herein in the specification, drawings, and claims, whether disclosed individually or in any desired combination, can be significant for the operation of the present invention in its various embodiments. Features from one embodiment can be used in other embodiments of the present invention.

[0035] like Figure 1A-Figure 3 As shown, an embodiment of the present invention includes a device for guiding certain adjacent assembly components to align relative to each other to position the assembly components into the positions they adopt when the assembly system is in an assembled configuration. The guiding device aligns certain structures in the adjacent assembly components to produce another structure, which is used to receive a fastening mechanism to connect the components together. After being guided into a predetermined assembly configuration, the guiding device can be removed so that the aligned assembly components are in an aligned predetermined configuration, which is suitable for receiving a fastening mechanism to secure the assembly components to each other in the aligned predetermined configuration.

[0036] Embodiments of the present invention are intended to accommodate assembly systems that include assembly components having certain features suitable for joining multiple assembly components; specifically, the components have at least one recess or opening on a side surface or outer surface, such as Figure 2 shown.

[0037] like Figure 2 As shown, the first assembly component 200 may have a top surface 210, an opposite bottom surface 220, and a center portion between the top and bottom surfaces. The first assembly component may also have a passage 230 extending between the top and bottom surfaces, with openings in the top and bottom surfaces. The second assembly component 300 may have a top surface 310, an opposite bottom surface 320, and a center portion between the top and bottom surfaces. At least one recess or hole 330 may be located on the top surface 310 of the second assembly component 300, extending into an interior portion of the second assembly component 300. When the first and second assembly components are aligned in a predetermined configuration, the channel or passage 230 of the first assembly component may communicate with the hole or recess 330 of the second component to define a cavity 400 suitable for receiving a fastening mechanism. In a preferred embodiment, the aligned cavity may have a size and shape suitable for receiving or engaging a stepped dowel.

[0038] The aligned dowel receiving cavity 400 (created by the alignment of the first assembly component 200 and the second assembly component 300) can have a series of cavity segments, including a first cavity segment 410 having a maximum perimeter or circumference, and each successive cavity segment 420a, 420b, 430, 440, 450 having a smaller perimeter or circumference than the previous segment. When viewed in profile, such an aligned dowel receiving cavity has a stepped or stepped shape having a base or entrance portion that is wider or larger than a tip portion on the opposite side.

[0039] The dowel receiving cavity 400 is formed by the alignment of the first assembly part 200 and the second assembly part 300. The dowel receiving cavity 400 can have a plurality of cavity sections, a first section 410, intermediate sections 420a, 420b, 430, 440, and a final section 450. In a preferred embodiment, the dowel receiving cavity has two intermediate sections, but other embodiments may have no intermediate sections, one intermediate section, or three or more intermediate sections. The first section 410 and the final section 450 can each have a side boundary and an end boundary. Each of the intermediate sections 420a, 420b, 430, 440 can each have a side boundary and a step boundary. Each cavity section is preferably adjacent to another adjacent section. The side boundaries define a cross-sectional dimension for their respective sections. In a preferred embodiment, the cross-sectional dimension of the side boundaries in a series of steps decreases as one proceeds from the first section 410 to the final section 450. The cross-sectional dimension of the side boundaries can be any suitable dimension. The length of each individual cavity section can vary greatly.

[0040] The dowel receiving cavities 400 are arranged in the assembly system at a non-perpendicular angle, a transverse angle, or an acute angle relative to the surface of the top end of the assembly system. Pairs of dowel receiving cavities can be arranged in the top end so as to define lines or paths extending toward each other. Each of the pairs of dowel receiving cavities can extend toward the longitudinal axis of the assembly system, or toward the longitudinal axis disposed between the holes. The pairs of holes can define angles relative to the top end surface that are between 0°-90°, and preferably the acute angles are between 30°-60° or between 40-50°.

[0041] To accommodate the stepped dowel 100, the corresponding dowel receiving cavity 400 may include a cavity composed of segments 410, 420a, 420b, 430, 440, 450, such that the first cavity segment 410 defines a cavity having a maximum perimeter or circumference, and each successive segment defines a cavity having a smaller perimeter or circumference than the previous segment. The concave space defined by the dowel receiving cavity 400 may have a stepped or stepped shape or profile, which is sized and shaped to receive the stepped dowel 100.

[0042] In the dowel receiving cavity 400, the hole may include a first cavity section 410 of the dowel receiving cavity 400 that is configured to engage a collar member, which will be described in more detail below.

[0043] In the case where the assembly system is a wall panel system, the first assembly component 200 and the second assembly component 300 may be, for example, a ceiling member 200 and a wall panel 300. For example, some wall systems are composed of multiple wall panels. A single panel may be too large or heavy to be easily manipulated by an individual alone or with the help of others, and the same may be true for a multi-panel wall assembly system. Such wall panels may include recesses or holes on their tops, bottoms, or sides that can be engaged by a fastening mechanism to fasten the wall panel to another wall system component, such as a floor member or a ceiling member.

[0044] The wall panel assembly may include a series of wall panels arranged in rows alongside one another, with longitudinally extending horizontal ceiling members and corresponding floor members affixing the top and bottom ends of the wall panels in place therebetween. Each wall panel may have a vertical length that is substantially greater than its horizontal height, thereby defining an elongated member or element. Sides of adjacent wall panels may be connected to one another, and when assembled together, adjacent surfaces of the positioned wall panels may define an outwardly facing surface of the wall panel assembly.

[0045] Each wall panel or elongated member 300 includes a top end and an opposite bottom end, and has first and second generally planar opposite surfaces 310 and 320 extending between the top and bottom ends, and first and second opposite side portions, such as Figure 2-Figure 3 At least one outer surface of the wall panel or elongated member 300, preferably the top end 310 thereof, may include one or more holes or recesses 330. Each hole may include an aperture on the surface of the wall panel that communicates with a passage extending inwardly from the surface into the interior portion of the wall panel 300. Preferably, the passage terminates within the interior portion of the wall panel 300.

[0046] Each ceiling member 200 may include an elongated first surface 210 and a second surface 220. Each surface member may include one or more pre-drilled (or otherwise formed) holes or channels defining a passage 230 extending between the first surface 210 and the second surface 220 of the ceiling member 200. Preferably, the channels are disposed at an angle, preferably an acute angle or a transverse angle, relative to the first and second surfaces, but the channels may also be disposed at substantially right angles relative to the first and second surfaces.

[0047] When the surface member 200 is placed against the wall panel 300, as shown Figure 3As shown, it is preferred that each channel is aligned with a corresponding hole so that the aligned two structures together define a space or cavity shaped to receive a dowel. In some embodiments, the channel and the hole can be aligned to define a generally straight or linear fastener receiving path.

[0048] In a preferred embodiment, the defined space or cavity 400 forms a space suitable for a stepped dowel. In this aligned configuration, the components can be secured together with a fastening mechanism (eg, a stepped dowel).

[0049] Example: Guiding device like Figure 1A-Figure 3 As shown, the guide device may include a stepped dowel member 100, as described in U.S. Patent Nos. 7,856,933 and 10,005,586, which are incorporated herein by reference. In short, the stepped dowel 100 is composed of a plurality of sections 110, 120, 130, 140, 150, with the first section 110 having the largest perimeter or circumference, and each successive section having a smaller perimeter or circumference than the previous section. When viewed in profile, such a dowel has a stepped or stepped shape, with a base portion 102 that is wider or larger than a tip portion 104 on the opposite side.

[0050] The dowel 100 may have a plurality of dowel sections, namely a first section 110, intermediate sections 120, 130, 140, and a final section 150. In a preferred embodiment, the dowel has two intermediate sections, but other embodiments may have no intermediate sections, one intermediate section, or three or more intermediate sections. The first dowel section 110 and the final dowel section 150 may each have a side wall and an end wall. Each of the intermediate sections 120, 130, 140 may each have a side wall and a step wall. Each section is preferably adjacent to another adjacent section. The side walls define a cross-sectional dimension for their respective sections. In a preferred embodiment, the cross-sectional dimension of the side walls in a series of steps decreases as one proceeds from the first section to the final section. The cross-sectional dimension of the side walls may be any suitable dimension. The length of each individual dowel section may vary widely. The dowel may have some or all sections with grooves on their outer surfaces. The dowels may have other configurations, such as the dowels shown and described in US Pat. No. 6,267,527, which is incorporated herein by reference.

[0051] Preferably, the stepped dowel member 100 can be assembled into the dowel receiving cavity 400 defined by the hole 330 of the aligned wall panel 300 and the channel 230 of the ceiling member 200 (or the dowel receiving cavity formed by two adjacent assembly components that have been aligned into a predetermined assembly configuration). Preferably, the stepped dowel member 100 and the dowel receiving cavity 400 form a loose fit therebetween. The loose fit between the stepped dowel member 100 and the dowel receiving cavity 400 is preferred so that the stepped dowel member 100 of the guide device can be easily and freely moved within the dowel receiving cavity 400, and so that the tip portion 104 of the stepped dowel member 100 can be easily and freely guided to the end of the dowel receiving cavity 400.

[0052] When the tip portion 104 is allowed to engage the wall panel component 300, the tip portion 104 of the stepped dowel member 100 has a size and shape that can be inserted into a hole in the wall panel without a floor component or a ceiling component, such as Figure 2 and Figure 3 Preferably, the tip portion 104 has a relative size and shape smaller than the hole 330 of the wall panel, so that the tip portion 104 can be easily inserted into the hole 330 of the wall panel.

[0053] In some embodiments, the stepped dowel component 100 may include a sensor for detecting when the hole 330 of the wall panel 300 and the channel 230 of the ceiling component 200 are sufficiently aligned to define the dowel receiving cavity 400. For example, the sensor may be included on the tip portion 104 or the last dowel section 150 of the stepped dowel component 100. Such a sensor may provide a signal to the individual using the guide device upon detecting the change in physical space created by the alignment of the hole 330 of the wall panel and the channel 230 of the ceiling component to communicate that the components have been aligned relative to each other.

[0054] The surface of the dowel section may be smooth or textured. For example, the sidewalls of the dowel sections of one or more stepped dowel members may include threads on their outer surfaces. The threads of the dowel member may engage with complementary threads or grooves on the side surfaces of the corresponding dowel receiving cavities.

[0055] The guide member includes a collar member 160 that surrounds a portion of the base portion 102 of the stepped dowel member 100. Preferably, the collar member 160 is proximate to the first section 110 of the stepped dowel member 100. In the case where the dowel section of the stepped dowel member has a cylindrical shape, the collar member 160 may also have a cylindrical shape surrounding the base portion 102 of the stepped dowel member 100.

[0056] like Figure 1A and Figure 1BAs shown, the collar member 160 may have a sidewall having a similar shape to the sidewall of the first section 110 of the stepped dowel member 100. The cross-sectional dimension of the sidewall of the collar member 160 is greater than the cross-sectional dimension of the first section 110 of the stepped dowel member 100; the cross-sectional dimension of the sidewall of the collar member 160 is greater than the cross-sectional dimension of all sections of the stepped dowel member 100. The collar member 160 has an upper end surface 162 facing the base 102 of the stepped dowel member 100 and a lower end surface 164 facing the tip 104 of the stepped dowel member 100. The upper end surface 162 and the lower end surface 164 may define an upper aperture and a lower aperture, respectively. The upper aperture and the lower aperture may provide a passage through which the stepped dowel member 100 may move.

[0057] In some embodiments, the upper aperture includes a flange 166 extending outwardly from the upper end surface 162. Such outwardly extending flange 166 preferably has a diameter or circumference greater than the diameter or circumference of the dowel receiving cavity 400 to limit the depth to which the guide member can enter the dowel receiving cavity 400. Thus, a portion of the guide member can always remain protruding above the passage of the ceiling member 200, even when the guide device is fully engaged to align the wall panel 300 and the ceiling member 200 into a predetermined alignment configuration. Figure 3 As shown, this feature prevents the guide from being lost through the hole 230 of the ceiling member 200.

[0058] In some embodiments, the upper aperture includes a rim or flange extending inwardly from the upper end surface. Such a rim or flange can limit the sliding movement of the collar member 160 relative to the stepped dowel member 100 so that the collar member 160 remains close to the first dowel section 110 (or base portion) of the stepped dowel member 100.

[0059] In some embodiments, the collar member 160 may have a lower step wall facing the tip 104 of the stepped dowel member 100. Such a flange may limit the sliding movement of the collar member 160 relative to the stepped dowel member 100 so that the collar member 160 always remains close to a portion of the base portion 102 of the stepped dowel member 100.

[0060] The guide device can have a shape and profile similar to the stepped dowel 100, wherein the collar member 160 provides a first section 110 of the stepped dowel shape of the guide device, the first dowel section 110 of the stepped dowel member 100 provides a second section of the guide device, the second dowel section of the stepped dowel member provides a third section of the guide device, and so on.

[0061] The collar member 160 may be attached to the stepped dowel member 100 so as to move in a sliding manner along the base portion 102 of the stepped dowel member.

[0062] The stepped dowel component 100 and the collar member 160 may include structures for reversibly securing the collar member 160 to the stepped dowel component 100. For example, the outer surface of the sidewall of the first section of the stepped dowel component 100 may include a grooved path for engaging a protrusion extending from the inner surface of the sidewall of the collar member 160. Such a protrusion may engage the grooved path, thereby minimizing or preventing movement of the collar member 160 relative to the stepped dowel component 100. The protrusion may disengage from the grooved channel, thereby allowing the collar member 160 to move relative to the stepped dowel 100. As another example, the collar member 160 may be reversibly coupled and uncoupled to the stepped dowel component 100 by any commonly used fastening mechanism, such as threads, snaps, or the like. Thus, the collar member 160 may not be fixed to move relative to the stepped dowel portion, or may be fixed to remain stationary relative to the stepped dowel portion, as desired.

[0063] In some embodiments, the collar member 160 and the stepped dowel member 100 may be configured such that the collar member 160 floats, slides, or moves relative to the stepped dowel member 100, such as Figure 1A-1B As shown. The collar member 160 can travel along the longitudinal axis of the stepped dowel member 100 or along the longitudinal axis of the first section 110 of the stepped dowel member 100. Therefore, the collar member 160 can move in a direction substantially parallel to the longitudinal axis. In some embodiments, the collar member 160 can rotate around the stepped dowel member 100. In some embodiments, an inwardly extending or outwardly extending flange depending from the upper surface of the collar member 160 can provide a structure to prevent the collar member 160 from being disengaged from the stepped dowel member 100.

[0064] Preferably, one or more dowel sections of the stepped dowel member 100 have side walls having a longitudinal length sufficient to span the distance over which the two assembly components undergo alignment via the guide when the two assembly components approach each other. Figure 2 As shown, for example, when the assembly components are aligned, a first dowel segment 110 and collar member 160 engage aperture 230 of ceiling component 200, while an adjacent dowel segment extends between channel 230 of ceiling component 200 and aperture 330 of wall panel 300, thereby providing a direct, linear connection between the two components. This direct, linear connection allows an individual to align the two assembly components relative to one another along a first plane and align the channels and apertures so that ceiling component 200 can be lowered onto wall panel 300 to achieve alignment in a second plane (and allow the channels and apertures to communicate to define a dowel-receiving cavity). Although Figure 2One particular dowel section is shown spanning the distance between the two assembly components, but other dowel sections may provide such primary and secondary alignment of the two assembly components relative to each other.

[0065] The base portion 102 of the stepped dowel member 100 may include a structure or member for providing a grip for a hand tool. For example, the base portion 102 of the stepped dowel member 100 may include a collar or ring that may be gripped by a hook or eye hook. As another example, the base portion 102 may include a protrusion that may be gripped by a hand tool, such as pliers or fingers. Similarly, the collar member 160 may include a structure protruding from the top end of the collar member 160 that extends away from the tip portion 104, thereby providing a structure for manipulating or retrieving a guide, such as an internal rod located near the upper aperture and extending away from the stepped dowel member 100, from the aligned first and second assembly components (e.g., the ceiling member 200 and the wall panel 300).

[0066] Example: Using a boot device Typically, after the wall panel is secured or mounted to the floor panel, the wall panel 300 and the ceiling member 200 are aligned into a predetermined alignment configuration. Figure 2 and Figure 3 As shown, typically the ceiling member 200 is lifted and then lowered onto the top surface 310 of the wall panel 300 or multi-panel wall system, with the bottom surface 220 of the ceiling member 200 meeting the top surface 310 of the wall panel 300 .

[0067] Generally, the ceiling member 200 will be suspended by a crane or other mechanical equipment, transported to a position close to the desired predetermined configuration, and suspended above the wall panel 300. The guide device can be deployed when the distance between two assembly components is small enough to be spanned by the guide device. For certain combinations of ceiling members and wall panels, the engagement distance between the two assembly components can be several inches, typically less than 12 inches, less than 6 inches, or about 1-2 inches. In other assembly systems, the guide device can be used to span larger or smaller distances. For example, the engagement distance between the assembly components can be less than the length of the longest dowel section of the guide device.

[0068] By using the guides while the weight of the ceiling member 200 is fully or partially supported by the crane, the individual attempting to align the assembly components needs to apply relatively little force to precisely move the ceiling member to the desired position. The individual can easily move heavy and large components, either manually or using other equipment. Once the ceiling member 200 is placed on the wall panel 300, the individual must use a greater amount of force to change the position of the ceiling member relative to the wall panel; in some cases, the ceiling member 200 may be too large or too heavy to be moved without assistance.

[0069] Before the bottom surface 220 of the ceiling member 200 and the top surface 310 of the wall panel 300 contact each other, the guide device can pass through the channel defining the passage 230 between the upper surface 210 and the lower surface 220 of the ceiling member 200. The tip portion 104 can pass through the channel. The dowel section of the stepped dowel member 100 can pass through the passage 230; the collar member 160 has a size or girth that is too large to allow the collar member to pass through the passage 230. Alternatively, the channel can be configured to engage the collar member 160, thereby preventing the guide device from completely passing through the channel 230. The hole can include a first cavity section 410 of the dowel receiving cavity 400, such first cavity section 410 being configured to engage the collar member 160.

[0070] After the collar member 160 engages the stepped channel 230, some or all of the dowel segments pass through the passage.

[0071] like Figure 2 As shown, as the ceiling component 200 approaches the wall panel 300, the protruding tip portion 104 of the stepped dowel component 100 can be manipulated to engage the orifice of the stepped hole 330 of the wall panel 300. As described above, the corresponding ceiling component channel 230 and wall component hole 330 can be aligned to define the dowel receiving cavity 400, which is configured to receive the stepped dowel 100.

[0072] Once engaged, Figure 3As shown, the tip portion 104 can slide or move along the side boundary of the hole 330, thereby guiding the remaining portion of the guide member further into the hole 330. Preferably, the collar member 160 has a thickness or cross-section sufficient to fully engage or tightly connect with the cavity section of the channel. The dowel section adjacent to or near the collar member 160 will have a thickness or cross-section that is less than the thickness or cross-section of the collar member 160. Preferably, the cross-section of the adjacent dowel section is smaller than the opening of the channel and the hole, and the cross-section is sufficiently smaller than the opening of the channel and the hole so that the adjacent dowel section can easily pass through the opening. That is, it is desired that the collar member 160 and the ceiling member 200 have a tight fit, while it is desired that the stepped dowel member 100 and the wall panel 300 have a loose connection.

[0073] As the tip portion 104 of the guide device is guided to the end of the hole 330 (which is in the interior portion of the wall panel 300), the guide device can manipulate the assembly components so that the guide device fully engages the dowel receiving cavity 400 in a manner that aligns the ceiling component 200 and the stepped dowel component 100 relative to each other and is positioned together in a predetermined alignment position for the assembled wall system 300. Once aligned, the hole 330 and the channel 230 can be positioned to communicate with each other to define the fastener receiving cavity 400, as shown in FIG. Figure 2 Because most of the weight of the ceiling member 200 is supported by the crane at this point in time, even if the ceiling member 200 has a large size or a heavy weight, the channel 230 and the hole 330 can be manipulated to be accurately aligned with each other.

[0074] When the guide device has aligned the ceiling member 200 and the wall panel 300, the side wall of the collar member 160 can be connected to the surface of the first section cavity 410 of the dowel receiving cavity 400, wherein the first cavity section 410 is located in the ceiling member 200. The last dowel section 150 of the stepped dowel member 100 can be connected to the last cavity section 450 of the dowel receiving cavity 400, wherein the last cavity section 450 is located in the wall panel 300. The cavity section between the first cavity section and the last cavity section can be located in the ceiling panel 200, the wall panel 300, or a portion of each structure.

[0075] like Figure 2 As shown, with the channels 230 and holes 330 positioned at right angles relative to the upper and lower surfaces of the ceiling member 200 and the wall panel 300, the guide means can align the two components to obtain a dowel receiving cavity 400 that is perpendicular to the two components. This precise alignment of the surfaces of the dowel receiving cavity 400 facilitates the subsequent placement of the fastening mechanism with a similar precise vertical alignment perpendicular to the upper surfaces of the assembled components. This feature allows the fastening mechanism to be positioned so that it is along the longitudinal axis of the dowel receiving cavity, as shown. Figure 2-Figure 3 shown.

[0076] In the dowel receiving cavity 400 , the hole may include a first cavity section 410 of the dowel receiving cavity 400 that is configured to engage the collar member 160 .

[0077] Due to the stepped shape of the dowel 100, the dowel can be inserted into the hole with minimal force. Preferably, the collar member 160 is sized and shaped to tightly engage the channel 230 of the ceiling member, while the one or more stepped dowel sections are sized and shaped to loosely engage the hole 330 of the wall panel 300.

[0078] Where there are multiple, corresponding holes and passages to be aligned, more than one guide arrangement may be used to align the ceiling member and wall panel into a predetermined aligned configuration.

[0079] After the desired configuration or alignment is achieved, the guide device can be removed from the aligned components so that their relative alignment is maintained or preserved. That is, the guide device can be removed from the aligned components without disturbing the position of the aligned first and second components (e.g., ceiling components and wall panels).

[0080] The guide device or its components may be constructed of plastic, metal or any other type of material that will ensure proper operation of the guide device. The guide device may also be constructed of a combination of two or more materials. For example, the guide device may be constructed of wood and include a metal post or insert that passes longitudinally and axially through the guide device from the base to the tip. One embodiment of the guide device may be constructed of a metallic material or metal alloy, such as hardened steel, stainless steel or titanium.

[0081] Specific embodiments of the guide device for assembling a system according to the present invention have been described for the purpose of illustrating the manner in which the present invention can be made and used. It should be understood that other variations and modified embodiments of the present invention and its different aspects will be apparent to those skilled in the art, and the present invention is not limited to the specific embodiments described. Features described in one embodiment may be implemented in other embodiments. It should be understood that any and all modifications, variations or equivalents that fall within the spirit and scope of the present invention and the basic underlying principles disclosed and claimed herein are included.

[0082] The present invention also provides the following items: 1. A device for guiding a first assembly component and a second assembly component into an assembled configuration, the guiding device comprising: a dowel member having: a base portion; a tip portion; and a plurality of dowel sections, each successive dowel section having a cross-section that is smaller than the cross-section of a preceding dowel section; and a collar member disposed about and slidably engaged with the base portion of the dowel member; wherein the first assembly component includes a channel and the second assembly component includes a hole, such that when the first assembly component and the second assembly component are aligned in the assembled configuration, the channel and the hole define a cavity configured to receive a stepped dowel; and Wherein the assembly components are positioned in a predetermined configuration by engaging i) the collar member to the channel of the first assembly component and ii) the stepped dowel member to the aperture of the second assembly component.

[0083] 2. The guide device according to item 1, wherein the collar member comprises a flange having a cross section larger than a cross section of the collar member.

[0084] 3. The guide device according to item 1, wherein the base portion of the dowel member includes a member for providing a grip for a hand tool.

[0085] 4. The guide device according to item 1, wherein the dowel receiving cavity comprises a plurality of cavity segments, each successive cavity segment having a cross-section that is smaller than the cross-section of the previous cavity segment.

[0086] 5. The guide device according to item 4, wherein the collar member is for engaging a first cavity section in the first assembly component, and the dowel section is for engaging a cavity section in the second assembly component.

[0087] 6. The guiding device according to item 4, wherein: The dowel-receiving cavity includes four cavity sections; and The dowel member includes three dowel sections.

[0088] 7. The guiding device according to item 4, wherein: The dowel receiving cavity is composed of four cavity sections; and The dowel member consists of three dowel sections.

[0089] 8. The guide device according to item 1, wherein the guide device comprises a metal material.

[0090] 9. The guide device according to item 1, wherein the dowel member comprises a metal material.

[0091] 10. The guiding device according to item 1, wherein: The first assembly component includes a ceiling member; and The second assembly component includes a wall panel.

[0092] 11. A method for assembling a wall system, comprising: providing a wall panel having a hole on a top surface, the hole of the wall panel being adapted to engage a stepped dowel; providing a ceiling member having opposing elongated upper and lower longitudinal surfaces and a dowel cavity extending through the longitudinal surfaces; positioning a guide member to engage the cavity of the ceiling member, the guide member having a plurality of dowel sections, each successive dowel section having a cross-section that is smaller than a cross-section of a previous dowel section; positioning a guide member to engage the hole of the wall panel, one end of the guide member engaging the cavity of the ceiling member and another end of the guide member engaging the hole of the wall panel; positioning the ceiling member and the wall panel in a predetermined orientation; removing the guide device; and The stepped dowels are inserted into dowel receiving cavities defined by the aligned cavities of the ceiling components and the holes of the wall panels, thereby connecting the aligned ceiling components to the aligned wall panels and assembling the wall system.

[0093] 12. The wall system assembly method according to item 11, comprising: An adhesive material is applied to the dowel receiving cavity or the dowel such that the adhesive material is ultimately disposed in the dowel receiving cavity.

[0094] 13. A wall system assembly method according to item 11, wherein the guide means comprises a collar member surrounding and slidingly engaging the dowel section, the collar member having a cross section larger than the cross section of the dowel section.

[0095] 14. The wall system assembly method according to item 11, wherein the guide device comprises a metal material.

[0096] 15. A wall system assembly method according to item 11, wherein the base portion of the guide device includes a member for providing a grip for a manual tool.

[0097] 16. The wall system assembly method of clause 11, wherein the guide member comprises a collar member slidingly engaging the first dowel section, the collar member having a cross-section greater than a cross-section of the first dowel section.

[0098] 17. The wall system assembly method according to item 11, wherein the stepped dowel comprises a plurality of dowel sections, wherein: The first dowel section of the guide member has a cross-section that is smaller than the cross-section of the first section of the stepped dowel; The second dowel section of the guide member has a cross-section that is smaller than the cross-section of the second dowel section of the stepped dowel; and The cross section of the last dowel section of the guide member is smaller than the cross section of the last dowel section of the stepped dowel.

[0099] 18. A device for guiding a first assembly component and a second assembly component into a predetermined configuration, the guiding device comprising: a stepped dowel member having a plurality of dowel sections, each successive dowel section having a cross-section that is smaller than the cross-section of the previous dowel section; and a collar member surrounding and slidingly engaging the first dowel section; wherein each assembly component includes a stepped opening such that when the assembly components are positioned in the assembled configuration, the aligned stepped openings define a cavity for receiving a stepped dowel; and wherein the assembly components are positioned in the assembled configuration by the stepped dowel member passing through the stepped opening of the first assembly component and into the stepped opening of the second assembly component such that the collar member engages the stepped opening of the first assembly component and the stepped dowel member engages the stepped opening of the second assembly component.

[0100] 19. The guiding device according to item 18, wherein the stepped dowel member comprises a sensor.

Claims

1. A system for guiding a first assembly component and a second assembly component into a predetermined configuration, the system comprising: a first assembly component and a second assembly component; and A guiding device, the guiding device comprising: a stepped dowel member having a plurality of dowel sections, each successive dowel section having a cross-section that is smaller than the cross-section of a preceding dowel section; and a collar member surrounding and slidingly engaging the first dowel section; wherein each assembly component includes a stepped opening such that when the first assembly component and the second assembly component are positioned in an assembled configuration, the aligned stepped openings define a cavity for receiving a stepped dowel; and wherein the first assembly component and the second assembly component are positioned in the assembled configuration by the stepped dowel member passing through the stepped opening of the first assembly component and into the stepped opening of the second assembly component such that the collar member engages the stepped opening of the first assembly component and the stepped dowel member engages the stepped opening of the second assembly component.

2. The system of claim 1, the stepped dowel member comprising a sensor.

3. A guiding device for guiding a first assembly component and a second assembly component into an assembled configuration, the guiding device comprising: A dowel member having: a base portion; Tip part; and a plurality of dowel segments, each successive dowel segment having a cross-section that is smaller than the cross-section of a previous dowel segment; and a collar member disposed about and slidably engaged with at least one of the plurality of dowel sections; Wherein the collar member is prevented from sliding in a direction toward the base portion of the dowel member when an upper end surface of the collar member abuts a lowermost surface of the base portion, the upper end surface being a topmost surface of the collar member.

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