Method and apparatus for panel edge coupling

• US 4,782,642 A
• Filed: 06/29/1987
• Issued: 11/08/1988
• Est. Priority Date: 06/29/1987
• Status: Expired due to Term

• Current Assignee: David J. Conville
• Original Assignee: David J. Conville
• Inventors: Conville, David J.
• Primary Examiner(s): Bell, J. Karl
• Application Number:
  US07/067,369
• Time in Patent Office: 498 Days
• Field of Search: 52/514, 52/489, 52/584, 52/703, 52/714, 52/98
• US Class Current: 52/770
• CPC Class Codes: E04F 13/081 with additional fastening elements between furring elements and covering elements
• CPC Class Codes: E04F 13/0841 the fastening elements engaging the outer surface of the covering elements, not extending through the covering E04F13/0839 and E04F13/0846 take precedence
• CPC Class Codes: E04G 23/02 Repairing, e.g. filling cracks; Restoring; Altering; Enlarging compositions of filling material C04B; strengthening, widening, repairing of bridges E01D22/00; drying damp layers by temporary mechanical ventilation E04B1/7092
• CPC Class Codes: E04G 23/0203 Arrangements for filling cracks or cavities in building constructions
• CPC Class Codes: E04G 23/0207 in hollow structures, e.g. cavity walls
• CPC Class Codes: E04G 23/0281 Repairing or restoring roofing or roof covering roof covering E04D3/00
• CPC Class Codes: F16B 5/0004 Joining sheets, plates or panels in abutting relationship F16B5/01 takes precedence

Abstract

Methods and apparatus for joining or repairing wall or ceiling panels such as sheet rock, gypsum boards, plywood, or other generally planar wall panels. Means are provided for permanently joining the edges of wallboard panels, ceiling panels, or the like at any desired position along the length of the wall frame or ceiling framework independent of framing backup studs or joists. Each embodiment of the invention contemplates the use of a plurality of metallic clips adapted to provide a working union or edgewise mechanical bond between adjacent panel edges, by creating an artificial backing in wall regions having no studs or support columns. A preferred clip comprises a generally planar, elongated body having a pair of parallel of reinforcement grooves, and the whole body is preferably stamped from perforated metal stock. A pair of integral, spaced apart, prong-like spring tab structures are formed on opposite sides of the clip body to grasp the edges of a panel. Each spring tab includes an integral, upwardly extending vertical portion disposed substantially perpendicularly to the body and an integral, outwardly curved substantially horizontal flange portion. The horizontal flange portion is separated from its vertical companion by a weakened, scored tear edge which permits manual weakening and removal of the flange by appropriate bending after clip installation. In the preferred clip the spring tabs project towards the clip front to maximize the working area of the body available for fastening to the second or later panels.

Claims

1. A construction method for securely coupling together adjacent panels of gypsum board, sheet rock, masonite, insulation board, plywood or the like, which panels have abutting finished edges which, during wall assembly, terminate at random positions spaced apart from the wall studs, support columns or the like, said method comprising the steps of:

conventionally installing a first panel upon and between spaced apart studs or vertical support columns during assembly with an exposed edge of said first panel randomly positioned apart from the nearest stud or vertical support column over a hollow region of the wall structure;

applying at least one clip to the exposed, finished panel edge to prepare said first panel for coupling to a second panel finished edge, each of said clips comprising;

a generally planar, perforated body portion adapted to be blindly penetrated by a self tapping screw, said body portion having a length greater than the thickness of said panel(s), a front, a rear, and a pair of spaced apart sides;

prong-like spring tab means integrally projecting from said clip body portion on opposite sides thereof, each of said spring tab means including a vertical portion generally perpendicular to said clip body portion and an integral offset horizontal flange portion oriented generally parallel with said clip body portion adapted to readily frictionally grasp a finished edge of a panel to sandwich same against said clip body;

said spring tab flange portions spaced apart from said clip body portion a distance approximately equal to or less than the thickness of said panel;

installing a self-tapping screw through said first panel substantially within a region defined between said spring tab means horizontal portions so as to penetratingly engage said clip body in a substantially random position thus permanently affixing said at least one clip to said first panel;

positioning a second panel having an exposed finished edge immediately adjacent to the exposed finished edge of said first panel over exposed planar portions of said at least one clip with said finished edges of said panels substantially abutting one another;

installing another self-tapping screw through said second panel immediately adjacent said spring tab means horizontal portions so as to permanently couple said second panel to said at least one clip body portion whereby said first and second panels are coupled together along their exposed finished edges with the clip(s) forming the sole backup structure for the adjacent panels without additional mechanical linkage to a stud, support column or the like; and

,

thereafter manually removing said horizontal flange portions of said spring tab means by bending them until breakage occurs along a predefined scored junction, whereby to ultimately construct an unobstructed wall surface for subsequent finishing.

2. The method as defined in claim 1 wherein the flange portions of said spring tab means are outwardly curved to compressively grip the panel edge when said clip is manually installed and to avoid penetration of the finished panel edge, and to facilitate subsequent manual manipulation, breakage and removal of the spring tab flanges.

3. The construction method as defined in claim 2 wherein said clips include a plurality of parallel reinforcing grooves defined along the length of said clip body portion.

4. A method for securely repairing randomly located holes in panels of gypsum board, sheet rock, masonite, insulation board, plywood or the like without mechanical connection to or support from the internal, spaced apart wall studs, support columns or the like, said method comprising the steps of:

defining and locating a hole in said panel to be repaired;

applying a plurality of clips at spaced apart locations about the internal periphery of said hole to be repaired, each of said clips comprising;

a generally planar, perforated body portion adapted to be blindly penetrated by a self tapping screw, said body portion having a length significantly greater than the thickness of said panel(s), a front, a rear, and a pair of spaced apart sides;

prong-like spring tab means integrally projecting from said clip body portion on opposite sides thereof, each of said spring tab means including a vertical portion generally perpendicular to said clip body portion and an integral offset horizontal flange portion oriented generally parallel with said clip body portion adapted to readily frictionally grasp said panel to sandwich same against said clip body;

said spring tab flange portions spaced apart from said clip body portion a distance approximately equal to or less than the thickness of said panel;

whereby a plurality of clips may be initially installed about the periphery of said hole to be repaired;

installing a self-tapping fastener through said wall substantially within regions defined between said spring tab means horizontal portions so as to penetratingly engage each clip body portion to permanently affix them;

positioning an appropriately shaped repair piece within said hole over said clips;

installing a self-tapping fastener through regions of said repair piece immediately adjacent said spring tab means horizontal portions so as to permanently couple said repair piece to said clips whereby said repair piece is permanently secured to the wall within said hole without additional mechanical linkage to a stud, support column or the like; and

,

thereafter manually removing said horizontal flange portions of said spring tab means by manually bending them until breakage occurs along a predefined scored junction, whereby to ultimately construct an unobstructed wall surface for subsequent finishing.

5. The method as defined in claim 4 wherein the flange portions of said spring tab means are outwardly flared to compressively grip the edges of a hole to be fixed when clips are installed and to facilitate manual manipulation thereof.

6. The method as defined in claim 5 wherein said clips include at least one reinforcing groove defined along the length of said clip body portion.

7. A fastener clip for enabling the coupling together of adjacent panels of gypsum board, sheet rock, masonite, insulation board, plywood or the like which have abutting finished edges which, during construction of a wall, end up randomly positioned relative to spaced apart wall studs, support columns or the like, said clip comprising:

a generally planar body portion comprised of perforated metal, said body portion having a length significantly greater than the thickness of said panel, a front, a rear, a pair of spaced apart sides, and at least one reinforcing groove extending generally along its length;

prong-like spring tab means integrally projecting from said clip body portion on opposite sides thereof for compressively clamping said clip about an exposed edge of said panel, each of said spring tab means comprising;

a vertical portion generally perpendicular to said clip body portion;

an integral, arcuate, offset horizontal flange portion oriented generally parallel with said clip body adapted to readily grasp an edge of a panel and to sandwich same against said clip body without penetrating the panel;

said spring tab flange portions spaced apart from said clip body portion a distance approximately equal to or less than the thickness of said panel; and

,

said horizontal flange portions of said spring tab means being separated from the vertical portions thereof by a scored junction which facilitates manual bending of said flanges until they break away from said body for removal;

said spring tab flanges generally defining a region about said panel for installing a self-tapping fastener through said panel substantially within said region whereby to penetratingly engage said clip body portion to permanently affix said clip to said first panel; and

,

said clip body having an exposed portion immediately adjacent to the exposed edge of said first panel over which at least a portion of a second panel may be laid and into which another fastener may be installed to permanently couple two or more panels together.

8. The clip as defined in claim 7 wherein the flange portions of said spring tab means are outwardly flared to compressively grip and avoid penetration of the panel edge when said clip is installed and to facilitate manual manipulation and removal of the flanges.