WALL PLUMBING AND LEVELING DEVICE

Description

TECHNICAL FIELD

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.

BACKGROUND

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.

SUMMARY

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.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a wall plumbing and leveling device.

FIG. 2 is a top view of the wall plumbing and leveling device disposed around a wall stud.

FIG. 3 is a top view of an alternative L-shaped wall plumbing and leveling device disposed around the wall stud.

FIG. 4A is a side view of the wall plumbing and leveling device correcting a wall stud that is leaning out at the top.

FIG. 4B is a side view of the wall plumbing and leveling device correcting a wall stud that is kicked in at the bottom.

FIG. 4C is a side view of the wall plumbing and leveling device correcting a wall stud that is bowed in the middle.

FIG. 5 is an end view of a double-width wall plumbing and leveling device disposed around two wall studs.

FIG. 6 is an end view of two L-shaped wall plumbing and leveling devices disposed on a corner arrangement of a stud-framed wall.

FIG. 7 is a perspective view of a wall plumbing and leveling device.

FIG. 8 is a perspective view of the wall plumbing and leveling device of FIG. 7 disposed around a wall stud.

FIG. 9 is an end view of the wall plumbing and leveling device of FIG. 2 disposed around a wall stud.

FIG. 10 is an end view of an alternative L-shaped wall plumbing and leveling device disposed around a wall stud.

FIG. 11 is an end view of a double-width wall plumbing and leveling device disposed around two wall studs.

FIG. 12 is an end view of two L-shaped wall plumbing and leveling devices disposed on a corner arrangement of a stud-framed wall.

DETAILED DESCRIPTION

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 FIGS. 1-4 (comprising FIGS. 4A-4C), wall plumbing and leveling devices will be described. FIG. 1 is a perspective view of a wall plumbing and leveling device 100. FIG. 2 is an end view of the wall plumbing and leveling device 100 disposed around a wall stud 202.

As shown in FIGS. 1 and 2, the wall plumbing and leveling device 100 comprises a channel-shaped body 102 including a front face 102a and two side faces 102b, 102c disposed along edges of the front face 102a to form the channel-shaped body 102. The channel-shaped body 102 of the wall plumbing and leveling device 100 comprises a “U” shape. Each side face 102b, 102c includes multiple holes 104 therein. The holes 104 allow insertion of fasteners, such as nails, screws, self-tapping screws, or other suitable fastener, to attach the wall plumbing and leveling device 100 to a wall stud 202 (FIG. 2).

As shown in FIG. 2, the wall plumbing and leveling device 100 fits over an edge 202a of a stud 202. For a stud having a width W, the wall plumbing and leveling device 100 fits over a portion x of the width W of the stud 202, 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 102b, 102c of the wall plumbing and leveling device 100 can be designed to provide desired characteristics. For example, if the depth of the wall plumbing and leveling device 100 covers a larger portion x of the width W of the stud 202, the wall plumbing and leveling device 100 may be more securely attached to the stud 202. However, the wall plumbing and leveling device 100 only needs to cover a portion x of the width W of the stud 202 to provide sufficient structural strength for the wall finishes and to allow enough room for fasteners to attach the wall plumbing and leveling device 100 to the stud 202. Additionally, the wall plumbing and leveling device 100 can leave a sufficiently large portion y of the width W of the stud 202 uncovered to allow other trades to utilize the portion y for installation, or such that the wall plumbing and leveling device 100 does not interfere with materials already installed in the stud 202. For example, the portion y of the stud 202 can be utilized for running pipes, wire, ducts, or other materials, and the wall plumbing and leveling device 100 will not interfere with these materials in the stud 202. In one design, the depth of the side faces 102b, 102c of the wall plumbing and leveling device 100 are less than half the width W of the stud 202. In this manner, other trades may utilize the middle of the stud 202 to 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 102b, 102c can be 1.25 inches, which corresponds to the portion x of the width W of the stud 202. In this case, the wall plumbing and leveling device 100 will not extend over the middle of the width W of the stud 202. In other designs, the depth of the side faces 102b, 102c of the wall plumbing and leveling device 100 can equal to or be more than half the width W of the stud 202, as desired.

A width of the front face 102a of the wall plumbing and leveling device 100 corresponds to a thickness T of the stud 202. For example, for a typical 2×4 stud, the thickness T is 1.5 inches, and the interior width of the front face 102a is sized to separate the side faces 102b, 102c by at least 1.5 inches. The interior width of the front face 102a also can be sized slightly larger than the thickness T of the stud 202 (for example, 1.6 inches for a typical 2×4 stud) to allow easier installation of the wall plumbing and leveling device 100 over the edge 202a of the stud 202. The interior width of the front face 102a also 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 device 100 device 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 face 102a of 1.6 inches and a depth of the side faces 102b, 102c 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 device 100 can 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 holes 104 in the wall plumbing and leveling device 100 allow fasteners, such as screws, nails, bolts, or other suitable fastener, to be inserted therein to secure the wall plumbing and leveling device 100 to the stud 202. The holes may not be utilized in cases where the fasteners can penetrate the side faces 102b, 102c, such as when using nails, screws, or self-tapping screws that penetrate the side faces 102b, 102c without damaging the side faces 102b, 102c.

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 FIG. 3. FIG. 3 is an end view of an alternative L-shaped wall plumbing and leveling device 300 disposed around the wall stud 202. As shown in FIG. 3, the L-shaped wall plumbing and leveling device 300 comprises an L-shaped body 302 including a front face 102a and a side face 102b. The L-shaped wall plumbing and leveling device 300 includes all the features, and may be utilized in any manner, as described herein with reference to the wall plumbing and leveling device 100, except that the wall plumbing and leveling device 300 includes only a single side face 102b. The wall plumbing and leveling device 300 reduces 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 face 102a of the wall plumbing and leveling device 300 is not dependent on the thickness T of a stud 202 to which the wall plumbing and leveling device 300 is attached. The width of the front face 102a of the wall plumbing and leveling device 300 can be sized less than, more than, or equal to the thickness T of the stud 202 to which the wall plumbing and leveling device 300 is attached. To reduce material cost and weight, the width of the front face 102a of the wall plumbing and leveling device 300 can be less than the thickness T of the stud 202 to which the wall plumbing and leveling device 300 is attached, and the front face 102a of the wall plumbing and leveling device 300 can 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 300). 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 face 102a of the wall plumbing and leveling device 300 can be sized equal to or more than the thickness T of the stud 202 to which the wall plumbing and leveling device 300 is 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 face 102a can 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 102b, 102c can be increased or decreased as desired based on the corresponding stud, frame, header, or other item being corrected. Two wall plumbing and leveling devices 300 can be used on opposing sides of wider framing instead of forming a wall plumbing and leveling device having a very wide front face 102a.

For example, FIGS. 5 and 6 illustrate using the wall plumbing and leveling device for multiple studs (or thicker studs) and corners, respectively. FIG. 5 is an end view of a double-width wall plumbing and leveling device 500 disposed around two wall studs 202. The wall plumbing and leveling device 500 includes all the features, and may be utilized in any manner, as described herein with reference to the wall plumbing and leveling device 100, except that the wall plumbing and leveling device 500 comprises a channel-shaped body 502 comprising a wider front face 102a to accommodate the width of the two wall studs 202. In this manner, the width of the front face 102a can be sized to accommodate any desired width, such as multiple studs, the face of a stud or header, the thickness of a header, or any other desired application.

FIG. 6 is an end view of two wall plumbing and leveling devices 300 disposed on a corner arrangement of a stud-framed wall. As shown, each wall plumbing and leveling device 300 is disposed on a corresponding corner stud 202. Any suitable number of wall plumbing and leveling devices 300 can be utilized as needed to cover exposed corners of studs 202 in a stud-framed wall.

With reference to FIGS. 7-10, wall plumbing and leveling devices having a flange configuration will be described. FIG. 7 is a perspective view of a wall plumbing and leveling device 700. FIG. 8 is a perspective view of the wall plumbing and leveling device 700 disposed around a wall stud 202. FIG. 9 is an end view of the wall plumbing and leveling device 700 disposed around a wall stud 202. The wall plumbing and leveling device 700 includes all the features, and may be utilized in any manner, as described herein with reference to the wall plumbing and leveling device 100, except that the wall plumbing and leveling device 700 includes only flange faces 702d connecting the front face 102a to the side faces 102b, 102c.

As shown in FIGS. 7-9, the wall plumbing and leveling device 700 comprises a channel-shaped body 702 including a front face 102a and two side faces 102b, 102c. Each of the side faces 102b, 102c is connected to the front face 102a by a corresponding flange face 702d disposed along edges of the front face 102a and the side faces 102b, 102c to form the channel-shaped body 102. The channel-shaped body 702 of the wall plumbing and leveling device 700 also comprises a “U” shape. Each side face 102b, 102c includes multiple holes 104 therein. The holes 104 allow insertion of fasteners, such as nails, screws, self-tapping screws, or other suitable fastener, to attach the wall plumbing and leveling device 100 to a wall stud 202 (FIGS. 8-9).

The flange faces 702d extend at an angle A outwardly from edges of the side faces 102b, 102c to corresponding edges of the front face 102a, and the flange faces 702d meet the edges of the front face 102a at an angle B. In this manner, the flange faces 702d allow the front face 102a to have a wider profile than the edge of the stud 202 (or studs) over which the wall plumbing and leveling device 700 is disposed. This wider face 102a provides a larger and more stable surface area to which the finishes may be attached. Additionally, the angles A, B allow the side faces 102b, 102c to flex outwardly, thereby making installation over the edge 202a of the stud 202 easier, particularly for studs having larger variations in their sizing due to quality control measures. A width of the flange faces 702d between the front face 102a and the corresponding side faces 102b, 102c, and/or the size of the angles A, B, can be made smaller or larger to increase or decrease the width of the front face 102a.

As shown in FIGS. 8-9, the wall plumbing and leveling device 700 fits over an edge 202a of a stud 202. As discussed with reference to FIG. 2 for the wall plumbing and leveling device 100, aspects of the wall plumbing and leveling device 700 can be sized as desired. With reference to the dimension labels of FIG. 2, for a stud having a width W, the wall plumbing and leveling device 700 fits over a portion x of the width W of the stud 202, 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 102b, 102c, including the flange faces 702d, of the wall plumbing and leveling device 700, can be designed to provide desired characteristics. For example, if the depth of the wall plumbing and leveling device 700 covers a larger portion x of the width W of the stud 202, the wall plumbing and leveling device 700 may be more securely attached to the stud 202. However, the wall plumbing and leveling device 700 only needs to cover a portion x of the width W of the stud 202 to provide sufficient structural strength for the wall finishes and to allow enough room for fasteners to attach the wall plumbing and leveling device 700 to the stud 202. Additionally, the wall plumbing and leveling device 700 can leave a sufficiently large portion y of the width W of the stud 202 uncovered to allow other trades to utilize the portion y for installation, or such that the wall plumbing and leveling device 700 does not interfere with materials already installed in the stud 202. For example, the portion y of the stud 202 can be utilized for running pipes, wire, ducts, or other materials, and the wall plumbing and leveling device 700 will not interfere with these materials in the stud 202. In one design, the depth of the side faces 102b, 102c, including the corresponding flange portions 702d, of the wall plumbing and leveling device 700 are less than half the width W of the stud 202. In this manner, other trades may utilize the middle of the stud 202 to 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 102b, 102c, including the corresponding flange faces 702d, can be 1.25 inches, which corresponds to the portion x of the width W of the stud 202. In this case, the wall plumbing and leveling device 700 will not extend over the middle of the width W of the stud 202. In other designs, the depth of the side faces 102b, 102c, including the corresponding flange faces 702d, of the wall plumbing and leveling device 700 can equal to or be more than half the width W of the stud 202, as desired. Additionally, the width of the flange faces 702d, and/or the size of the angles A, B, can be made smaller or larger to increase or decrease the depth of the side faces 102b, 102c.

A width of the front face 102a of the wall plumbing and leveling device 700 is larger than a thickness T (FIG. 2) of the stud 202. An interior width w between the two side faces 102a, 102b of the wall plumbing and leveling device 700 corresponds to the thickness T (FIG. 2) of the stud 202. For example, for a typical 2×4 stud, the thickness T is 1.5 inches, and the interior width w is sized to separate the side faces 102b, 102c by at least 1.5 inches. The interior width w of also can be sized slightly larger than the thickness T of the stud 202 (for example, 1.6 inches for a typical 2×4 stud) to allow easier installation of the wall plumbing and leveling device 700 over the edge 202a of the stud 202. The interior width w also 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 device 700 device can be manufactured for different applications. For example, for a typical 2×4 stud wall, the wall plumbing and leveling device 700 can be manufactured with an interior width w of 1.6 inches and a depth of the side faces 102b, 102c, including the corresponding flange portions 702c, 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 device 700 can 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 holes 104 in the wall plumbing and leveling device 700 allow fasteners, such as screws, nails, bolts, or other suitable fastener, to be inserted therein to secure the wall plumbing and leveling device 700 to the stud 202. The holes may not be utilized in cases where the fasteners can penetrate the side faces 102b, 102c, such as when using nails, screws, or self-tapping screws that penetrate the side faces 102b, 102c without damaging the side faces 102b, 102c.

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 FIG. 10. FIG. 10 is an end view of an alternative L-shaped wall plumbing and leveling device 1000 disposed around the wall stud 202. As shown in FIG. 10, the L-shaped wall plumbing and leveling device 1000 comprises an L-shaped body 1002 including a front face 102a and a side face 102b. An edge of the side face 102b is connected to an edge of the front face 102a via a flange face 702d, as discussed previously with reference to FIGS. 7-9. The L-shaped wall plumbing and leveling device 1000 includes all the features, and may be utilized in any manner, as described herein with reference to the wall plumbing and leveling devices 100, 300, and 700, except that the wall plumbing and leveling device 1000 includes only a single side face 102b. The wall plumbing and leveling device 1000 reduces material cost and installation cost, while providing a plumb and level surface to which finishes can be attached. Additionally, the front face 102a, the flange 702d, and the side face 102b can be size as desired as described previously herein with reference to the wall plumbing and leveling devices 300 and 700.

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 face 102a can 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 102b, 102c, and corresponding flanges 702d, can be increased or decreased as desired based on the corresponding stud, frame, header, or other item being corrected. Two wall plumbing and leveling devices 1000 can be used on opposing sides of wider framing instead of forming a wall plumbing and leveling device having a very wide front face 102a.

For example, FIGS. 11 and 12 illustrate using the wall plumbing and leveling device for multiple studs (or thicker studs) and corners, respectively. FIG. 11 is an end view of a double-width wall plumbing and leveling device 1100 disposed around two wall studs 202. The wall plumbing and leveling device 1100 includes all the features, and may be utilized in any manner, as described herein with reference to the wall plumbing and leveling device 700, except that the wall plumbing and leveling device 1100 comprises a channel-shaped body 702 comprising a wider front face 102a to accommodate the width of the two wall studs 202. In this manner, the width of the front face 102a can be sized to accommodate any desired width, such as multiple studs, the face of a stud or header, the thickness of a header, or any other desired application.

FIG. 12 is an end view of two wall plumbing and leveling devices 1000 disposed on a corner arrangement of a stud-framed wall. As shown, each wall plumbing and leveling device 1000 is disposed on a corresponding corner stud 202. Any suitable number of wall plumbing and leveling devices 300 can be utilized as needed to cover exposed corners of studs 202 in a stud-framed wall.

The wall plumbing and leveling devices described herein can be formed of any suitable material sufficient to attach to a stud and to provide structural support for finishes. For example, steel, aluminum, or other metals and alloys, as well as plastics, polymers, and other synthetic materials may be utilized. For metals, the wall plumbing and leveling device may be formed from a sheet of metal by cutting the metal to size and then bending the side faces 102b, 102c (or a single face 102b or 102c) away from the front face 102b to form the channel-shaped body 102, 502, 702, 1102 or the L-shaped body 302, 1002, or any suitable configuration, of the wall plumbing and leveling device. The type and thickness of the metal can be chosen to provide the desired structural strength for the wall plumbing and leveling device. In one design, 20-gauge steel can be utilized. 20-gauge steel allows standard drywall or backer board screws to be used for installation of finishes directly to the front face 102a of the wall plumbing and leveling device. For synthetic materials, the wall plumbing and leveling device can be molded into the desired shape/profile.

FIGS. 4A-4C are side views of the wall plumbing and leveling device 100 correcting various deficiencies in a wall stud 202. In FIGS. 4A-4C, the entire side of the stud 202 is visible even though a portion of each stud 202 is covered by the wall plumbing and leveling device 100, which shows how the wall plumbing and leveling device 300 corrects the deficiencies in each stud 202.

FIG. 4A is a side view of the wall plumbing and leveling device 100 correcting a wall stud 202 that is leaning out at the top. As shown, the stud 202 is not plumb, as the top of the stud is leaning over the bottom of the stud. The wall plumbing and leveling device 100 is positioned plumb over the stud 202, which results in the wall plumbing and leveling device 100 covering more of the top of the stud 202 than the bottom of the stud 202 to correct the deficiency in the stud 202. The wall plumbing and leveling device 100 is attached to the stud 202 in this position, resulting in the front face 102a of the wall plumbing and leveling device 100 being plumb.

FIG. 4B is a side view of the wall plumbing and leveling device 100 correcting a wall stud 202 that is kicked in at the bottom. As shown, the stud 202 is not plumb, as the top of the stud is leaning back from the bottom of the stud. The wall plumbing and leveling device 100 is positioned plumb over the stud 202, which results in the wall plumbing and leveling device 100 covering less of the top of the stud 202 than the bottom of the stud 202 to correct the deficiency in the stud 202. The wall plumbing and leveling device 100 is attached to the stud 202 in this position, resulting in the front face 102a of the wall plumbing and leveling device 100 being plumb.

FIG. 4C is a side view of the wall plumbing and leveling device 100 correcting a wall stud 202 that is bowed in the middle. As shown, the stud 202 is not plumb, as the middle of the stud is bowed outwardly and extends further out in the middle than it does at the top and the bottom. The wall plumbing and leveling device 100 is positioned plumb over the stud 202, which results in the wall plumbing and leveling device 100 covering more of the middle of the stud 202 than the bottom or the top of the stud 202 to correct the deficiency in the stud 202. The wall plumbing and leveling device 100 is attached to the stud 202 in this position, resulting in the front face 102a of the wall plumbing and leveling device 100 being plumb.

To correct a wall having multiple studs that are not level which each other, when correcting the deficiencies of the studs (for example, as described with reference to FIGS. 4A-4C), the depth of insertion of each wall plumbing and leveling device 100 over the corresponding stud 202 can be manipulated such that the front face 102a of each wall plumbing and leveling device 100 is also horizontally level with the front face 102a of each other wall plumbing and leveling device 100.

The wall plumbing and leveling devices on each wall can be manipulated during installation to make adjacent walls square with each other.

After pluming and leveling the wall, and squaring the wall with other walls, the finishes can be attached to the wall(s) by attaching the finishes to the front faces of the wall plumbing and leveling devices (and in some cases also to the edge of studs or other framing that did not require correction).

The wall plumbing and leveling device 300 can be utilized to correct wall deficiencies in a similar manner as described herein by attaching its single side face 102b to the studs 202. Additionally, other configurations of the wall plumbing and leveling device, such as those configurations depicted in FIGS. 7-12, can be utilized to correct wall deficiencies in a similar manner as described herein.

Although described herein as being useful for stud-framed walls, the wall plumbing and leveling device described herein is useful for any stud-framed structure, such as walls, ceilings, floors, or any other stud-framed structure. These structures may be framed with studs or, in some cases, may be framed with joists, headers, door frames, window frames, etc. In these cases, the operation of the wall plumbing and leveling device is the same with joists or other framing as described herein with reference to studs, and the terms studs and joists may be used interchangeably herein and in the claims. Additionally, the terms wall, ceiling, and floor may be used interchangeably herein and in the claims.

The wall plumbing and leveling device described herein can be utilized with any desired framing. Wood and metal are commonly used materials in construction framing, and the wall plumbing and leveling device described herein can be utilized with these materials and others. The wall plumbing and leveling device described herein is useful for any construction materials, such as wood, metal, composites, or other suitable construction materials, as long as a suitable fastener is utilized to attach the wall plumbing and leveling device to the construction materials.

Clause 1. A plumbing and leveling device as described herein.

Clause 2. A method to plumb and/or level a stud in a wall as described herein.

Clause 3. A method to plumb and level multiple studs in a wall as described herein.

Clause 4. A device to plumb and level construction materials, comprising: a body comprising a U-shaped profile comprising 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.

Clause 5.1. The device according to clause 4, 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.

Clause 5.2. The device according to clause 4, 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.

Clause 5.3. The device according to clause 4, 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.

Clause 5.4. The device according to clause 4, 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.

Clause 6. The device according to clause 4, 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.

Clause 7. The device according to clause 4, 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.

Clause 8. The device according to clause 4, 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.

Clause 9. The device according to clause 4, 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.

Clause 10. The device according to clause 4, 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.

Clause 11. The device according to clause 4, wherein each of the first side face and the second side face comprise a plurality of holes therein.

Clause 12. The device according to clause 11, 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.

Clause 13. A device to plumb and level construction materials, comprising: a body comprising a U-shaped profile comprising 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 comprising a plurality of holes therein that are sized to accommodate a fastener to attach the device to a stud.

Clause 14. A device to plumb and level construction materials, comprising: a body comprising: 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.

Clause 15. The device according to clause 14, wherein the device comprises an L-shaped profile.

Clause 16.1. The device according to clause 14, wherein the first side face is disposed orthogonally to the front face along the first edge of the front face.

Clause 16.2. The device according to clause 14, 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.

Clause 16.3. The device according to clause 14, further comprising a second side face disposed orthogonally to the front face and along the second edge of the front face, wherein the device comprises a U-shaped profile.

Clause 17. The device according to clause 14, wherein a width of the front face corresponds to a thickness of a stud to which the device is configured to attach.

Clause 18. The device according to clause 14, wherein a width of the front face is less than a thickness of a stud to which the device is configured to attach.

Clause 19. The device according to clause 14, 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.

Clause 20. The device according to clause 14, 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.

Clause 21. The device according to clause 14, wherein the first side face comprises a plurality of holes therein, each of the plurality of holes being sized to accommodate a fastener to attach the device to a stud.

Clause 22. A method to plumb and level studs in a stud-framed wall, comprising: providing a wall comprising a first stud and a second stud in a spaced-apart fashion, each of the first and second studs comprising 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 comprising a body comprising a U-shaped profile comprising 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.

Clause 23.1. The method according to clause 22, 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.

Clause 23.2. The method according to clause 22, 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.

Clause 24. The method according to clause 22, 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.

Clause 25. The method according to clause 22, wherein each of the first side face and the second side face of each of the first and second devices comprise 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.

The example systems, methods, and components described in the embodiments presented previously are illustrative, and, in alternative embodiments, certain components can be combined in a different order, omitted entirely, and/or combined between different example embodiments, and/or certain additional components can be added, without departing from the scope and spirit of various embodiments. Accordingly, such alternative embodiments are included in the scope of the following claims, which are to be accorded the broadest interpretation so as to encompass such alternate embodiments.

Although specific embodiments have been described above in detail, the description is merely for purposes of illustration. It should be appreciated, therefore, that many aspects described above are not intended as required or essential elements unless explicitly stated otherwise. Modifications of, and equivalent components or acts corresponding to, the disclosed aspects of the example embodiments, in addition to those described above, can be made by a person of ordinary skill in the art, having the benefit of the this disclosure, without departing from the spirit and scope of the invention defined in the following claims, the scope of which is to be accorded the broadest interpretation so as to encompass such modifications and equivalent structures.