Stackable hand-held butt board, system, and methods

Abstract

The present invention is a butt board comprising a recess-forming mean wherein the butt board defines a recessed surface on one side of an abutment joint formed between two associated sheets mating to each other along said recessed surface. The butt board has a stackable end portion and on one side defines a canal tail and opposing which is a retaining head for entry and retention into an adjacent butt board canal tail. The retaining head is sized and shaped to enter, by either one of pushing together and sliding into, the canal tail and be securely retained therein. Also shown are methods for mating two associated drywall sheets along a centrally disposed recessed surface, and hand-held methods for stacking and dismantling a plurality of butt boards into and out of a butt board stack.

Description

[0001] TITLE

[0002] STACKABLE HAND-HELD BUTT BOARD, SYSTEM, AND METHODS

[0003] FIELD OF THE INVENTION

[0004] The present invention is generally in the field of construction and more specifically butt boards to which adjoining members are abutted.

[0005] BACKGROUND

[0006] A butt board is nominally considered a piece of hardwood to which adjoining members are abutted.

[0007] Butt boards are known and used in ship construction as well as habitation / residential / commercial / industrial construction.

[0008] The present invention is best explained in context of drywall / gypsum board construction, but is applicable to any building or construction method / type involving a butt board.

[0009] Conventional drywall is fabricated in sheets having a gypsum core that is contained within a fibrous cardboard-like outer skin.

[0010] Drywall sheets conventionally shipped and sold in four feet (width) by eight feet (height) sheets.

[0011] Conventional frame-type construction involves assembling a structural portion of a wall or ceiling from a framework that is comprised of a plurality of joists, which are classically two inches (width) by four feet (length) pieces of lumber.

[0012] The dry wall must be fastened over the framework of joists to form the outer surface of the wall or ceiling.

[0013] Where the drywall sheets meet along a common butting edge forms a drywall abutment joint.

[0014] Since a number of drywall sheets will usually have to be applied to a particular wall or ceiling surface to completely cover the structural framework, the individual sheets of drywall will have to be joined together in a way that is not easily detectable to a viewer after the wall has been finished.

[0015] Also, these abutments typically occur in-between joists as opposed to perfectly midway over any given joist.

[0016] Moreover, where dry wall sheets normally abut (along the dry wall abutment joint), an elevated area remains visible after drywall taping and mud application.

[0017] To give drywall the appearance of co-planer connection (no visible bump or elevation when viewed from the side), it is necessary to use a butt board, and moreover a butt board that pulls each drywall sheet ever slightly inward (when fastened to the butt board) thereby creating a recess on an outer surface of the drywall abutment.

[0018] Such a butt board is able to pull each drywall sheet slightly inward because the butt board defines a recess forming means wherein the butt board has a recessed surface on an interior side of a dry wall abutment joint that is to be formed between an associated first and second drywall sheet.

[0019] Such a butt board defining said recess is known, and disclosed for example in House et al. (US2004 / 01111994 published June 17, 2004).

[0020] In operation / implementation, the dry wall joint is formed by placing a butt board behind an associated first drywall sheet, and the drywall sheet is then fastened to the butt board along a first butt edge.

[0021] A second associated dry wall sheet having a second butt edge is aligned to the first dry wall sheet along with the first butt edge and then fastened to the butt board.

[0022] As the butt board has a recessed surface, both drywall sheets will flex slight inward toward the butt board when fastened thereto, thereby defining a secondary recess in surfaces of the first and second drywall sheets along each butt edge interface.

[0023] The aspects of a recessed surface and secondary recess are well illustrated in Figs. 3 to 5 inclusive of House et al. as well as Ferguson (US5799458) at Fig. 4.

[0024] As the secondary recess is sub-planar to each of the other drywall sheets generally, the filling of the recess with drywall mud and tape will ultimately result in a planar finish.

[0025] To this extent butt boards are known but there still remains difficulties and problems even in these improved recessed butt boards.

[0026] One problem relates to the aspect that butt boards are sized to run a respectable length along a corresponding piece of dry wall (at the butt edge). Where a drywall sheet is four feet wide a corresponding butt board can be expected to be usually two feet long and close to four inches wide, so as to span a reasonable portion of the dry wall along the butt edge.

[0027] As prior art butt boards tend to be two feet long or longer, tradespeople are limited (whether by weight or volume or both) in the number of butt boards they can hold, carry, and implement during any given task and at any given time.

[0028] Also, there are limitations in installing butt boards while simultaneously keeping unused butt boards at the ready for rapid deployment.

[0029] Still yet other limitations of prior art butt boards include being limited to wood manufacture (and other heavy materials), susceptibility to moisture / water damage, and lacking easy visual installation guidance to accelerate and offer nearly "dummy-proof" assembly.

[0030] All prior art butt boards are conventionally not less than twenty-four inches long (two feet), bulky, heavy, and are intentionally made so because standardized construction industry conventionally requires "larger" and "sturdier" building pieces when it comes to residential and commercial building construction in particular.

[0031] SUMMARY

[0032] In one embodiment, the present invention is a butt board comprising a recess-forming mean wherein the butt board defines a recessed surface on one side of an abutment joint that is to be formed between two associated sheets mating to each other along said recessed surface. The butt board has a stackable end portion and on one side defines a canal tail and on the opposing side thereto defines a retaining head for entry and retention into an adjacent butt board canal tail.

[0033] The retaining head is sized and shaped to enter, by either one of pushing together (compressive force) and sliding (shearing force) into, the canal tail and be selectively retained therein.

[0034] The retaining head is also therefore be correspondingly sized and shaped to exit, by either one of pulling apart (expansive force) from and sliding (shearing) out of, the canal tail and be freed therefrom.

[0035] In another embodiment, the present invention is a method for mating two associated drywall sheets along a centrally disposed recessed surface defined by a butt board recess-forming mean wherein the butt board defines a stackable and a free end portion, and is sized for holding in one hand.

[0036] A plurality of butt boards are assembled in one hand by either of pushing and sliding together each butt board stackable end portion to form a butt board stack having a first butt board and a series of adjacent butt boards thereafter.

[0037] The butt board stack is placed astern the first drywall sheet by aligning the first drywall sheet abutment edge to the first butt board center portion.

[0038] At least one fastener is attached through the first drywall sheet and into the first butt board on the hand-held butt board stack. After securing the first dry wall sheet to the first butt board, the remaining butt board stack is detached from the first butt board by either of pulling or sliding apart the remaining butt board stack at the stackable end portion of the first butt board, leaving the first butt board attached to the first drywall sheet.

[0039] In yet another embodiment, the present invention is a hand-held method for stacking a plurality of butt boards into a butt board stack comprising providing a plurality of butt boards wherein each butt board is shaped to define a stackable end portion.

[0040] The stackable end portion on one side defines a canal tail and on the opposing side defines a retaining head sized and shaped for entry and retention into an adjacent butt board canal tail by either of pushing together and sliding thereinto.

[0041] The retaining head is correspondingly sized and shaped to exit, by either one of pulling apart and sliding out of, the canal tail to be freed therefrom.

[0042] The butt boards are each sized for holding in one hand, and this method provides for repeatedly either one of pushing together and sliding into the canal tail of a one butt board the retaining head of an adjacent butt board, for retention therein, and to form and grow the butt board stack.

[0043] In still yet another embodiment the present invention is conversely repeatedly detaching one butt board retaining head by either one of pulling apart and sliding out of the canal tail of an adjacent butt board and being freed therefrom, to disassemble and decrease said butt board stack. DRAWINGS

[0044] FIG. 1 A is a perspective view of one butt board.

[0045] FIG. IB is is a perspective view of the butt board shown in FIG. 1 with a user hand for environmental context.

[0046] FIG. 2 is a flip-side perspective view of the butt board shown in FIG. 1.

[0047] FIG 3. is a front plan view of the butt board.

[0048] FIG 4. is front plan view showing two butt boards being snapped together by compressive force.

[0049] FIG. 5 is a front plan view of two butt boards stacked together.

[0050] FIG. 6 is a front plan view of two butt boards being disconnected by expansive force.

[0051] FIG. 7 is a perspective view of two stacked butt boards separated by shearing force.

[0052] FIG. 8 is a cross section view showing three stacked butt boards in operation at a first stage.

[0053] FIG. 9 is a cross section view showing three stacked butt boards in operation at a second stage.

[0054] FIG. 10 is a cross section view showing three stacked butt boards in operation at a third stage. FIG. 11 is a cross section view showing three stacked butt boards in operation at a fourth stage.

[0055] FIG. 12 is a cross section view showing two stacked butt boards being disconnected from the third butt board in operation at a fifth stage.

[0056] FIG. 13A is a cross-section view showing a single butt board in operation at a final stage using two fasteners per abutment face.

[0057] FIG. 13B is a cross-section view showing a single butt board in operation at a final stage using only one fastener per abutment face.

[0058] DESCRIPTION

[0059] FIG. 1 A shows the present inventive butt board (10) generally in perspective view.

[0060] The present butt board (10) is sized for holding in a user's single hand (120) (FIG. IB), with a possibility to stack a plurality of butt boards (10) together while being retained within said same single hand (120).

[0061] The butt board (10) is best made from a moisture-resistant, rigid-flexible material, examples of which include in no specific or preferred order (and depending on variety and treatment) wood, aluminum, rubber, tin, glass, synthetic polymer, and particularly poly-vinyl chloride.

[0062] The butt board (10) generally features a tapered end portion (20) opposing a stacking end portion (30).

[0063] The stacking end portion (30) itself is distinguishable for defining a head portion (40) and a tail portion (50).

[0064] In one optimized embodiment it is preferable the stacking end portion (30) be tapered in the lead-up to the opposing head (40) / tail (50) combination, resulting in less material usage and less weight.

[0065] Generally centrally disposed is a longitudinal stabilizing ridge (60) that is sized and shaped for mating within an adjacent butt board (10) stabilizing canal (70).

[0066] In one disclosed embodiment the ridge (60) and canal (70) are configured for a basic malefemale relationship, thus relatively stabilizing or limiting movement in one plane while permitting movement in another plane.

[0067] Optimal exploitation of this butt board (10) takes advantage of each physical aspect of the butt board (10).

[0068] In one embodiment, the tapered end portion (20) of the butt board results in a reduced occupancy volume, weight, size, a stacked configuration (such as FIGS. 8 - 13), and provides a limited range of movement / freedom resulting in both protection of subsequent adjacent butt boards (10) as well as the user's hand (120) when in operation.

[0069] In that embodiment the stacking end portion (30) is comprised of the head portion (40) opposing the tail portion (50). The head portion (40) is best sized for easy snap fit (by compressive force) into an adjacent butt board (10) tail portion (50), or is otherwise capable of sliding into the tail portion (50) (see FIG. 7); the head portion (40) is very slightly reduced in size therefrom to provide a small degree of rotational freedom within the tail portion (50) when stacked together.

[0070] The head portion (40) need not be shaped as disclosed in the present drawings but the head portion (40) must be compatible with the corresponding tail portion (50) such that the head (40) and tail (50) can have a reciprocating male-female action, meaning the head (40) is situated at the least to be attachable / detachable with the tail (50) to mate and retain same in a stacked configuration.

[0071] The head (40) and tail (50) male-female relationship can be such that the head (40) may either slide in / out (by shearing force) of the tail (50) or instead snap-together / apart (compressive and expansive force) to and from the tail (50), or both slide in / out and snap-together / apart).

[0072] One significant principle of the head (40) and tail (50) portions is that they cooperate, typically in a male-female fashion, in order to connect and retain one another and then selectively disconnect by hand-held operation or any suitable mechanical / mechanized gripping device (to this end, a programmed robot could use and install these butt boards (10) in a "hand-held" fashion).

[0073] The very slight decrease in the head portion (40) size as compared to the tail portion size (50) allows for easy "snap-together" as well as easy "slide-apart" functions, as well as the ability to grasp a single butt board (10) arranged in a stacked configuration, and transport same knowing the remaining butt boards (10) will remain hanging flexibly without coming apart (short of a threshold expansive or shearing force) - see FIG. 5 as an example / approximation. In an embodiment shown the head portion (40) can be described as having a bulb-shaped profile (male), while the tail portion size (50) is the corresponding negative (female) profile to the bulb-shaped profile - a bulb and socket-type / male-female fit.

[0074] Also, the stabilizing ridge (60) is designed to slide or mate into the stabilizing canal (70) of an adjacent butt board (10), and this results in a horizontal stability when held within the user hand (120) - again see FIG. 5 as an example / approximation.

[0075] The "snap-together" action is no different than an applied compressive force, while the "slide- in" / "slide-out" action is no different than an applied shear force (in one direction versus an opposing direction), and so these terms are used interchangeably herein and as appropriate.

[0076] The butt board (10) presents on one side a first abutment face (130) and second abutment face (150), and opposing thereto a first abutment rear (140) and a second abutment rear (160).

[0077] The distinction in the abutment faces (130, 150) and abutment rears (140, 160) is that in deployment any fasteners (90) enter through either of the first associated dry wall sheet (170) and the second associated drywall sheet (180) and through the abutment faces (130, 150) in a direction toward the abutment rears (140, 160) - see FIG. 8-13.

[0078] The abutment faces (130, 150) and the gap between stacked butt boards (10) due to the tapered end portion (20) result in user hand (120) protection from accidental sticking or piercing, because the abutment face (130) receives the brunt of the fastener (90) and the gap space astern the first abutment rear face (140) places a user's hand (120) at a safe distance outside of fastener (90) reach.

[0079] In one embodiment the stacking end portion (30) itself presents a partial tapering, resulting in both less material as well as a gap for safety upon penetration of a fastener (90); the partial tapering of the stacking end portion (30) is offset by the opposing head (40) / tail (50) combination.

[0080] FIGS. 8-13 demonstrate the butt boards (10) being deployed in a hand-held stacked configuration by first aligning the first associated dry wall sheet (170) aside the stabilizing ridge (60) of the bottom-most (or "first") butt board (10) in the stack (Fig. 8).

[0081] A first fastener (90) is then fastened into and through the first associated dry wall sheet (170) and the bottom-most butt board (10) through the first abutment face (130) and exiting the first abutment rear (140).

[0082] At this point there are two options - one is to use one conventional fastener (90) per each abutment face (130, 150) meaning two fasteners (90) in total (FIG. 13B); and the second option is to use two fasteners (90) per abutment face (130, 150) meaning four fasteners (90) in total (FIG. 13A).

[0083] In the first option a single fastener (90) is positioned midway between the stabilizing ridge (60) and the tapered end portion (20) terminus, as in FIG. 13B.

[0084] In many applications, a single fastener (90) (FIG. 13B) per abutment face (130, 150) is likely sufficient in terms of construction sturdiness.

[0085] In the second option, a first fastener (90) is positioned nearer the tapered end portion (20) terminus, to provide sufficient space and dry wall (170, 180) strength for a second fastener (90) to pierce through the dry wall (170) and butt board (10) in the same direction but nearer the central ridge (60) (see Figs. 10, 11, and 13 A). The use of two fasteners (90) per each abutment face (130, 150) results in a total of four fasteners (90) and a stronger bond between the dry wall sheets (170, 180) and the butt board (10).

[0086] The stacked butt boards (10) are held within a user's hand (120) while in deployment.

[0087] In driving the second fastener (90) into the bottom-most butt board (10), and in part because the corresponding retaining head portion (40) being slightly smaller in size relative to the adjacent receiving tail portion (50), the stack of butt boards (10) are able to slightly and easily flex within a user's hand (120), thus bringing subsequent butt boards (10) away from the second fastener (90) and preventing damage to same.

[0088] Upon insertion of the second fastener, FIG. 11, 12 and 13 demonstrate how the remaining stack can simply be pried apart using expansive force (thus snapping out the remaining butt boards (10)) as shown in FIG. 5 and FIG. 6, or can likewise be slid apart using shearing force as generally disclosed and described in FIG. 7.

[0089] It is similarly possible that after insertion of only one fastener (90) that a user might decide to separate the now fastened butt board (10) from the remaining stack, but doing so would be less pragmatic than first assuring a strong bond with insertion of the second fastener (90).

[0090] At this stage a user has an option to place yet another butt board (10) somewhere along the desired edge of the first associated drywall sheet (170).

[0091] The user would still have a stack of remaining butt boards (10) within their hand (120) and so would easily be able to move to the next location and continue installing butt boards (10). If for example the first associated dry wall sheet (170) is four feet wide a user may desire to repeat the preceding actions at approximately every twelve inches or whatever other spacing according to their desire or building code.

[0092] Thereafter (meaning after an appropriate number of butt boards (10) have been mated to the first associated dry wall sheet (170)), the second associated dry wall sheet (180) can also be aligned to the central ridge (60), and so is automatically placed in position for two fasteners (90) to consecutively be driven through the drywall sheet (180) into the second abutment face (150) and through the second abutment rear (160) of each of the butt boards (10) available as per the preceding installation stage.

[0093] Advantageously, visually a user will know exactly where to apply said fasteners (90), with the first associated dry wall sheet (170) now acting as an anchor and stabilizing force for the attached butt boards (10) such that the butt boards (10) need not be hand-held in order to ensure proper attachment of the second associated drywall sheet (180).

[0094] FIG. 13 best demonstrates the result of four fasteners (90) forcing the abutment of two associated dry wall sheets (170, 180), with same resulting in an inward draw of both dry wall sheets (170, 180) to define a somewhat sunken triangular gap (100).

[0095] If left in this state, then rather than bulging like the prior art, the dry wall (170, 180) would instead appear to "sink" at the point of abutment.

[0096] Therefore, conventionally the abutment is finished off by the addition of either drywall mud / tape / both (110) to give a "flat" or co-planar appearance (instead of what would have been a bulging appearance otherwise). Because the butt boards (10) are small and light, they provide sufficient strength for their primary function of joining drywall (170, 180) securely, yet can be carried around in larger quantity (as compared to the prior art) more quickly and can be more rapidly deployed.

[0097] The stacking / compressive / expansive / sliding / shearing actions of this butt board (10) also accelerate production speed as gathering multiple butt boards (10) together for use becomes a quick and efficient task, while also allowing for quick and easy storage in a stable stacked configuration without occupying a large volume.

[0098] While obviously the size of a human hand (120) can vary among our population, generally a butt board (10) of not much more than six inches in length (see reference measurement X for example in FIG. 1 A) and three inches in width (see reference measurement Y for example in FIG. IB) would still accomplish one of the many improvements in this present invention and still generally be considered hand-held with an understanding of some variance and tolerance across the size of human hands.

[0099] While it is possible to make the present butt boards (10) even larger than six by three inches, such arbitrary size increases begin to defeat one of the (many) advantages in the present invention, namely that the present butt boards (10) are smaller, lighter, stackable, and easier to both transport and implement given their relatively smaller size (compared to the prior art).

[0100] The present butt boards (10) could be made larger than six by three inches to accommodate niche markets such as large-handed contractors but such construction would (as width and length increase) become a self-defeating stunt - more and larger material would make the device larger and more impractical, especially regarding the hand-held aspect. In one optimized embodiment said butt board (10) can, when made from poly-vinyl chloride for example, be four inches in length and less than two inches in width - and still be sufficient for almost universal construction standards (in terms of rigidity and security) while remaining hand-held, light, portable, stackable, storable and easily transportable.

Claims

CLAIMSWhat is claimed is:

1. A butt board comprising: a recess-forming mean wherein the butt board defines a recessed surface on one side of an abutment joint that is to be formed between two associated sheets mating to each other along said recessed surface; the butt board having one stackable end portion and one free end portion, wherein the stackable end portion on one side defines a canal tail and the stackable end portion on the opposing side defines a retaining head for entry and retention into an adjacent butt board canal tail; wherein the retaining head is sized and shaped to enter, by either one of pushing together and sliding into, the canal tail and be securely retained therein; and wherein the retaining head is sized and shaped to exit, by either one of pulling apart and sliding out of, the canal tail and be freed therefrom.2 The butt board in claim 1 wherein the retaining head is sized and shaped for limited lateral and pivotal movement within the canal tail.3 The butt board in claim 1 wherein the butt board is less than six inches in length.4 The butt board in claim 1 wherein the butt board is less than three inches in width.5 The butt board in claim 1 wherein the butt board is sized to be held by a user in one hand.

6. The butt board in claim 1 wherein the butt board is made from any one selected from a group of wood, rubber, tin, aluminum, glass, synthetic polymer, and poly-vinyl chloride.

7. The butt board in claim 1 further comprising the recessed surface on one side of the abutment joint defining a centrally disposed longitudinal stabilizing ridge for nesting against an adjacent butt board having a centrally disposed longitudinal stabilizing canal to receive said stabilizing ridge therein.8 The butt board in claim 1 wherein either butt board end portion tapers.9 The butt board in claim 1 wherein the first and second sheets are drywall sheets.10 A method for mating two associated drywall sheets along a centrally disposed recessed surface defined by a butt board recess-forming mean wherein the butt board defines a stackable and a free end portion, and is sized for holding in one hand, comprising: assembling in one hand a plurality of said butt boards by either of pushing and sliding together said butt board stackable end portions to form a butt board stack having a first butt board and a series of adjacent butt boards thereafter; placing the butt board stack astern the first drywall sheet aligning a first drywall abutment edge on the first drywall sheet to the first butt board center portion; attaching at least one fastener through the first drywall sheet and into the first butt board on the hand-held butt board stack to secure the butt board to the first drywall sheet; and after securing said first drywall sheet to the first butt board, thereafter detaching the remaining butt board stack from the first butt board by either of pulling or sliding apart the remaining butt board stack at the stackable end portion of the first butt board, leaving the first butt board attached to the first dry wall sheet.

11. The method in claim 10 further comprising placing and aligning the second dry wall sheet having an abutment edge adjacent the first dry wall sheet along the first dry wall abutment edge to form a common abutment seam, and atop the first butt board.

12. The method in claim 11 further comprising attaching at least one fastener through the second drywall sheet and into the first butt board.

13. The method in claim 12 further comprising applying and leveling drywall mud along the common abutment seam.

14. The method in claim 13 further comprising applying and leveling drywall tape along the common abutment seam.

15. A hand-held method for stacking a plurality of butt boards into a butt board stack comprising: providing a plurality of butt boards wherein each butt board is shaped to define a stackable and a free end portion; wherein the stackable end portion on one side defines a canal tail and on the opposing side defines a retaining head sized and shaped for entry and retention into an adjacent butt board canal tail by either of pushing together and sliding into; wherein the retaining head is sized and shaped to exit, by either one of pulling apart and sliding out of, the canal tail to be freed therefrom; wherein the butt boards are each sized for holding in one hand; and repeatedly inserting one butt board retaining head by either one of pushing together and sliding into the canal tail of an adjacent butt board, for secure retention therein, to form and grow the butt board stack.

16. A hand-held method for disassembling a plurality of butt boards from a butt board stack comprising: providing a plurality of pre-stacked butt boards wherein each butt board is shaped to define a stackable and a free end portion; wherein the stackable end portion on one side defines a canal tail and on the opposing side defines a retaining head sized and shaped for entry and retention into an adjacent butt board canal tail by either of pushing together and sliding into; wherein the retaining head is sized and shaped to exit, by either one of pulling apart and sliding out of, the canal tail to be freed therefrom; wherein the butt boards are each sized for holding in one hand; and repeatedly detaching one butt board retaining head by either one of pulling apart and sliding out of the canal tail of an adjacent butt board and being feed therefrom, to disassemble and decrease said butt board stack.

17. A butt board system comprising: a plurality of associated butt boards for adjacent stacking within a user hand for placement adjacent an associated dry wall sheet for affixing thereto, wherein each butt board defines a recessed surface on one side of an abutment joint that is to be formed between two associated sheets mating to each other along said recessed surface; each butt board having one stackable end portion and one free end portion, wherein the stackable end portion on one side defines a canal tail and the stackable end portion on the opposing side defines a retaining head for entry and retention into an adjacent butt board canal tail; wherein the retaining head of each butt board is sized and shaped to enter, by either one of pushing together and sliding into, the canal tail of the adjacent butt board and be securely retained therein; andwherein the retaining head of each butt board is sized and shaped to exit, by either one of pulling apart and sliding out of, the canal tail of the adjacent butt board and be freed therefrom.

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