TECHNICAL FIELD OF THE INVENTION
The present disclosure is related to the field of carpet stretching apparatuses, in particular, hand-operated tools for use in stretching carpet to aid in its installation.
BACKGROUND OF THE INVENTION
It is known to use hand-operated tools to stretch carpet to aid in its installation. Such tools are cumbersome and often require considerable physical strength on the part of the installer. Different carpet stretching tools are often required depending on the type of carpet being installed and where it is installed.
It is, therefore, desirable to provide an apparatus for stretching carpet that is easy to operate and includes accessories that allow a single apparatus to be used in installing in various configurations and applications.
SUMMARY OF THE INVENTION
An apparatus for stretching carpet is provided in the description herein. In some embodiments, the apparatus can comprise a rail having a fixed pin block operatively disposed at one end thereof, the pin block configured with a plurality of pins further configured to engage the backing of the carpet thereby enabling the pin block to grip or otherwise releasably attach to the carpet. In some embodiments, the pin block can comprise the pin block as described and shown in U.S. Pat. No. 7,237,764 issued on Jul. 3, 2007, said patent incorporated into this application by reference in its entirety.
In some embodiments, the pin block can comprise a parallelepiped baseblock that can further comprise a plurality of pins extending downwardly from the bottom surface of the baseblock. The pins can be linearly aligned in a single file along the bottom surface of the baseblock. Each pin extending from the baseblock can be encased in a cylindrical pin support such that only the pin tip is exposed and protruding downward from the end surface of the pin support, which can be adapted for contacting a carpet backing. In some embodiments, each baseblock can comprise between two to eight pin supports. In other embodiments, each baseblock can comprise between four to six pin supports. In a representative embodiment, the baseblock can comprise five pin supports.
In some embodiments, each pin support can be canted towards the front surface of the baseblock as it extends downward. In further embodiments, the pin supports can be canted at an angle of approximately 75° to approximately 45° with respect to the bottom surface. In a representative embodiment, this angle can be approximately 60°.
In some embodiments, a fin can extend between each adjacent pair of pin supports that intersects with the bottom surface. The pin block can further comprise a strengthening gusset extending between the bottom surface and the pin support closest to the front surface. Each fin can comprise a downward edge that is flush with the end surface of the pin supports whereby the combination of the end surfaces and the downward edges of the fins can form a single continuous contact surface that is substantially parallel to the bottom surface.
In some embodiments, the combination of the fins and the pins supports can extend approximately ⅜″ to approximately ⅝″ downward from the bottom surface of the baseblock. Each pin tip can extend approximately ⅛″ from the end surface of its pin support.
In some embodiments, each baseblock can comprise a protrusion extending from one side surface and a recess on the other side surface whereby the protrusion of one pin block can releasably interlock with the recess of another pin block. Therefore, a number of pin blocks can be releasably interlocked and aligned together to form a ganged pin block for a carpet gripping device, the ganged pin block having superior gripping power over a single pin block.
In operation, a number of pin blocks can be stacked together side by side to form a ganged gripping block installed in a carpet gripping device. The ganged block can be placed on the carpet with each pin tip piercing the carpet backing but the depth of penetration limited by the length of the pin tip and the contact surface formed by the fins and the end surfaces. The depth of the fins and pin supports can be set to accommodate the typical height of the fibers of the carpet. The length of the pin tip can be selected to penetrate the carpet backing but not to extend through the carpet backing and perforate any membrane on the bottom layer of the carpet backing or to tear the underlay as the carpet is stretched into position.
In some embodiments, the apparatus can further comprise a travelling mechanism disposed on the rail, the mechanism further comprising a second pin block disposed thereon that can work in cooperation with the fixed pin block. The mechanism can be configured to travel in a one-way direction on the rail when a lever disposed on the mechanism is operated.
In some embodiments, the apparatus can be further configured so that the travelling mechanism can move away from the fixed pin block with the fixed and second pin blocks configured with the pins facing away from each other whereby carpet can be stretched between the two pin blocks. The apparatus can also be further configured so that the travelling mechanism can move towards the fixed pin block with the fixed and second pin blocks configured with the pins facing towards each other whereby two pieces of carpet can be stretched towards each together to be seamed together using a carpet seaming tool.
In some embodiments, the apparatus can comprise one at least one support rod disposed on the apparatus to guide the movement of the travelling mechanism. In some embodiments, the apparatus can comprise a housing to enclose the travelling mechanism. In further embodiments, the housing can comprise at least one passageway through which the at least one support can pass through to guide the movement of the travelling mechanism. In some embodiments, the housing can further comprise means for releasably attaching to an extension tube that can further comprise a third pin block. The extension tube can be of varying lengths, depending on the application the apparatus is being used for. With a short extension tube installed, the apparatus can be used for stretching and installing carpet on stairs. With a long extension tube installed, the third pin block can comprise a backstop wherein the apparatus can be configured as a deadman stretcher for stretching wider expanses of carpet.
Broadly stated, in some embodiments, an apparatus is provided, comprising: a longitudinal rail having first and second ends; a first bracket disposed on the first end, and a second bracket disposed on the second end; a first pin block foot disposed on the first bracket, the first pin block configured to grip a first patch of carpet; a travelling module operatively disposed on the rail, the travelling module further comprising means for moving the travelling module along the rail; and a second pin block foot disposed on the travelling module, the second pin block configured to grip a second patch of carpet wherein operating the moving means causes the second pin block foot to move the second patch of carpet relative to the first patch of carpet.
Broadly stated, in some embodiments, a carpet installation tool is provided, comprising: a longitudinal rail having first and second ends; a first bracket disposed on the first end, and a second bracket disposed on the second end; a first pin block foot disposed on the first bracket, the first pin block configured to grip a first patch of carpet; a travelling module operatively disposed on the rail, the travelling module further comprising means for moving the travelling module along the rail; and a second pin block foot disposed on the travelling module, the second pin block configured to grip a second patch of carpet wherein operating the moving means causes the second pin block foot to move the second patch of carpet relative to the first patch of carpet.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view depicting a first embodiment of a carpet stretching apparatus;
FIG. 2 is an upper perspective view depicting the carpet stretching apparatus of FIG. 1;
FIG. 3 is a side elevation view depicting the carpet stretching apparatus of FIG. 1;
FIG. 4 is a side elevation view depicting the carpet stretching apparatus of FIG. 3 as it is being operated;
FIG. 5 is a perspective view depicting an alternate embodiment of the operating mechanism of a carpet stretching apparatus;
FIG. 6A is a side elevation view depicting the operating mechanism of the depicting the carpet stretching apparatus of FIG. 1;
FIG. 6B is a side elevation view depicting the operating mechanism of FIG. 6A as it is being operated;
FIG. 6C is a side elevation view depicting the operating mechanism of FIG. 6A as it is being released;
FIG. 7A is a side elevation view depicting the operating mechanism of the depicting the carpet stretching apparatus of FIG. 5;
FIG. 7B is a side elevation view depicting the operating mechanism of FIG. 7A as it is being operated;
FIG. 7C is a side elevation view depicting the operating mechanism of FIG. 7A as it is being released;
FIG. 8A is a perspective view depicting the carpet stretching apparatus of FIG. 1 with a stretcher tube;
FIG. 8B is a perspective view depicting the carpet stretching apparatus of FIG. 5 with a stretcher tube;
FIG. 9A is a perspective view depicting the carpet stretching apparatus of FIG. 1 with a tail blade;
FIG. 9B is a perspective view depicting the carpet stretching apparatus of FIG. 5 with a tail blade;
FIG. 10 is a side elevation view depicting the carpet stretching apparatus of FIG. 9B;
FIG. 11 is a side elevation view depicting an alternate embodiment of the carpet stretching apparatus of FIG. 9A;
FIG. 12 is a side elevation view depicting the carpet stretching apparatus of FIG. 1 with extended legs;
FIG. 13 is a perspective view depicting the carpet stretching apparatus of FIG. 5 configured for stretching carpet on stairs;
FIG. 14 is a perspective view depicting the carpet stretching apparatus of FIG. 1 configured for stretching carpet on stairs;
FIG. 15 is a perspective view depicting the carpet stretching apparatus of FIG. 5 configured as a deadman stretcher with a backstop for stretching wider expanses of carpet;
FIG. 16 is a perspective view depicting the backstop of the carpet stretching apparatus of FIG. 15;
FIG. 17 is a top plan view depicting the backstop of FIG. 16;
FIG. 18 is a top plan view depicting the backstop of FIG. 16 in an angled position;
FIG. 19 is a side elevation view depicting a top plan view depicting the backstop of FIG. 16;
FIG. 20 is a perspective exploded view depicting the backstop of FIG. 16; and
FIG. 21 is a perspective exploded view depicting the backstop of FIG. 16.
DETAILED DESCRIPTION OF THE INVENTION
Referring to FIGS. 1 through 4, an embodiment of a carpet stretching apparatus, denoted as apparatus 10, is illustrated. Apparatus 10 can comprise travelling module 12 slidably disposed on rail 14 whereby module 12 can move linearly along rail 14. In some embodiments, module 12 can comprise a travelling mechanism as shown in PCT Publication No. WO 2005/056240, published 23 Jun. 2005, and in United States Publication No. 2008/053262, published 6 Mar. 2008, both of which documents are incorporated by reference into this application in their entirety. Disposed at one end of rail 14 can be bracket 20. On the other end of rail 14, there can be disposed bracket 22. Pin block holders 26 can be disposed on the bottom side of bracket 20 and module 12, respectively. Pin block holders 26 can be configured to receive at least one pin block 28. In a further embodiment, pin block holders 26 can be configured to each hold one or more pin blocks 28 stacked side to side to form a ganged pin block. In yet a further embodiment, pin block 28 can comprise the pin blocks as described and claimed in U.S. Pat. No. 7,237,764. In another embodiment, apparatus 10 can further comprise one or more support rods 24 disposed between brackets 20 and 22. The addition of support rods 24 can provide additional rigidity to apparatus 10 to prevent rail 14 from bowing when apparatus 10 is in use. Referring to FIG. 4, when force F is applied downwardly to handle 16, handle 16 can pivot about handle pivot 30 to apply force to pin 34 disposed on module 12. In so doing, module 12 can advance along direction D on rail 14 as shown in FIG. 4. When force F is released from handle 16, handle 16 can return to an upright position and module 12 is then fixed in a stationary position on rail 14. When force is applied to release handle 18 pivotally attached to module 12 at release pivot 32, module 12 can be released from its position on rail 14 and can be manually moved in either direction along rail 14. It is obvious to those skilled in the art that apparatus 10 can be configured such that module 12 can advance in a direction opposite to direction D on rail 14 when force F is applied to handle 16.
Referring to FIG. 5, an alternate embodiment of apparatus 10 is shown. In some embodiments, support rods 24 can be substantially aligned with rail 14 in a horizontal plane. In some embodiments, pin 25 can be used to stabilize support rods 24 with respect to rail 14 by passing through rods 24 and rail 14 near each of brackets 20 and 22. In some embodiments, module 12 can comprise grooves 13 on its sidewalls to partially receive support rods 24 as a means for guiding module 12 as it travels along rail 14. In some embodiments, the application of downward force F on lever 16 causes module 12 to move along direction D as shown in FIG. 5.
Referring to FIGS. 6A, 6B and 6C, one embodiment of operating mechanism 36 disposed in module 12 is shown. Operating mechanism 36 is a device that can provide one-way linear travel along rail 14. When force F is applied to handle 16, thereby imparting force on pin 34 disposed on mechanism 36, module 12 can advance along rail 14 along direction D. Mechanism 36 and rail 14 can be of any suitable equivalent mechanism or rail as well known to those skilled in the art. In some embodiments, rail 14 and mechanism 36 can comprise the rail and travelling mechanism as used in Irwin model XP600 “Quik Grip™” bar clamp/spreaders, as manufactured by Irwin Industrial Tool Company, A Division of Newell Rubbermade, Inc. of 10 B Glenlake Parkway, Atlanta, Ga., U.S.A. When release force R is applied to release handle 18, module 12 can be released from rail 14 and then be manually moved along rail 14 in either direction.
Referring to FIGS. 7A, 7B and 7C, another embodiment of operating mechanism 36 disposed in module 12 is shown. In some embodiments, operating mechanism 36 can be disposed in housing 35. Housing 35 can further comprise passageways 33 disposed therethrough to permit support rods 24 to pass therethrough to guide module 12 as it moves along rail 14. In some embodiments, housing 35 can further comprise tube receiver neck 37 as attachment means for receiving or releasably attaching an extension tube that can be inserted in neck 37. In further embodiments, neck 37 can comprise aperture 39 for receiving a spring-loaded locking pin disposed on the extension tube to releasably connect the extension tube to housing 35. When force F is applied to handle 16, module 12 can advance along rail 14 along direction D. When release force R is applied to release handle 18, module 12 can be released from rail 14 and then be manually moved along rail 14 in either direction.
Referring to FIG. 8A, an embodiment of apparatus 10 showing a complement of other attachments is shown. In some embodiments, apparatus 10 can further comprise a stretcher tube 40 having backstop 38 mounted at an end thereof. The use of stretcher tube 40 and backstop 38 enables apparatus 10 to stretch a broader expanse of carpet. Apparatus 10 can further comprise bracket 50 having pin block holder 26 attached thereto further comprising at least one pin block 28. Bracket 50 can further comprise tail blade holder 46 having tail blade 48 attached thereon. The use of tail blade 48 enables apparatus 10 to work with a tack strip mounted on a floor when installing carpet thereon, as well known to those skilled in the art.
Referring to FIG. 8B, another embodiment of apparatus 10 showing a complement of other attachments is shown. In some embodiments, apparatus 10 can further comprise a stretcher tube 40 having backstop 38 mounted at an end thereof. The use of stretcher tube 40 and backstop 38 enables apparatus 10 to stretch a broader expanse of carpet. Apparatus 10 can further comprise bracket 50 having pin block holder 26 attached thereto further comprising at least one pin block 28. Bracket 50 can further comprise tail blade holder 46 having tail blade 48 attached thereon. The use of tail blade 48 enables apparatus 10 to work with a tack strip mounted on a floor when installing carpet thereon, as well known to those skilled in the art.
Referring to FIGS. 9A, 9B and 10, other embodiments of apparatus 10 are shown for use with tack strip 58 installed on floor 60. FIG. 9A shows one embodiment of apparatus 10. FIG. 9B shows another embodiment of apparatus 10. Bracket 50 can further comprise tail blade 48 attached directly to bracket 50 by having threaded knob 52 pass through an opening (not shown) disposed on tail blade 48, and into bracket 50. Tension knob 52 can be tightened to secure tail blade 48 to bracket 50. This arrangement can also allow tail blade 48 to pivot on tension knob 52, which can allow apparatus 10 to stretch carpet at an angle with respect to tack strip 58, which can be grasped by tail blade 48.
Referring to FIG. 11, an alternate embodiment of apparatus 10 as shown in FIGS. 9 and 10 is illustrated. In some embodiments, apparatus 10 can further comprise spacer 54 disposed between bracket 50 and tail blade 48, and spacer 56 disposed between module 12 and pin block holder 26. This embodiment enables apparatus 10 to be elevated above the floor so as to allow a carpet seaming tool (not shown) to pass under rail 14 between spacers 54 and 56.
Referring to FIG. 12, another embodiment of apparatus is shown. In some embodiments, apparatus 10 can further comprise bracket 50 disposed on one end of rail 14 having spacer 64 disposed between bracket 50 and pin block holder 26. Module 12 can further comprise spacer 62 disposed between module 12 and another pin block holder 26. This embodiment of apparatus 10 enables a carpet seaming tool (not shown) to pass under rail 14 between spacers 62 and 64. Apparatus 10 is used in this configuration to bring adjoining pieces of carpet together so that they can be seamed in a continuous fashion.
Referring to FIG. 13, another embodiment of apparatus 10 is shown. In some embodiments, apparatus 10 can be used for stretching carpet on stair treads. In this configuration, apparatus 10 can comprise adaptor 66 disposed between bracket 20 and pin block holder 26. Module 12 can further comprise extension tube 68 inserted into neck 37. Tube 68 can be held in place in neck 37 by spring-loaded locking pin 69 passing through pin aperture 39. To remove extension tube 68 from housing 35, pin 69 can be depressed such that it clears aperture 39 thereby allowing tube 68 to be removed from neck 37. Extension tube 68 can comprise adaptor 70 attached to the far end thereof and further comprise another pin block holder 26 disposed on the bottom thereof. In this configuration, when handle 16 is operated, pin block holders 26 can move away from each other thereby stretching the carpet therebetween for proper installation on a stair tread.
Referring to FIG. 14, another embodiment of apparatus 10 is shown. In some embodiments, apparatus 10 can be used for stretching carpets on a stair tread from the front of the step to the rise of the following step. In some embodiments, bracket 22 can further comprise support stand 72, which can allow apparatus 10 to be supported by a lower stair tread while stretching carpet on the stair tread from front to rear.
Referring to FIG. 15, another embodiment of apparatus is shown. In some embodiments, apparatus 10 can comprise extension tube 40 operatively attached to module 12 at one end, and that further comprises backstop 38 at the other end thereof. Apparatus 10 can be further configured to allow extension tube 40 to releasably connect with module 12. In the illustrated embodiment, backstop 38 will move away from pin block holder 26, operatively attached to adaptor 66 and bracket 20, when handle 16 is operated.
Referring to FIGS. 16 through 21, an embodiment of backstop 38 is shown. In some embodiments, backstop 38 can be configured with a central backstop unit 74 and with modular extension units 76 operatively attached on either end thereof. Central unit 74 can be pivotally attached to clevis joint 78 having channel lock 80 that can be configured to releasably attach to extension tube 40. In a further embodiment, tension knob 82 can pass through an opening disposed in clevis 78 and clevis receiver 86 into a central clevis receiver 86. Clevis receiver 86 can be operatively attached to central unit 74 using fasteners as well known to those skilled in the art. These can include but are not limited to screws, bolts, socket head screws, thumb screws, threaded knobs, bayonet connectors, or any other functionally equivalent fasteners. In another embodiment, clevis receiver 86 can be configured to allow backstop 38 to be tilted to the left or to the right with respect to extension tube 40, as shown in FIG. 18.
Referring to FIG. 19, a side elevation view of one embodiment of backstop 38 is shown. In some embodiments, pin block 28 can be disposed in backstop 38 at an angle 84. Configuring backstop 38 with an angle pin block 28 allows backstop 38 to “bite-in” into a carpet when apparatus 10 is being operated to stretch the carpet. The operation of apparatus 10, when stretching carpet, will have the effect of bowing extension tube 40 upwards. In so doing, backstop 38 can rotate downwards thereby reducing angle 84 whereupon pin block 28 can “bite-in” into the carpet even further.
Referring to FIG. 21, an exploded view of extension unit 76 of backstop 38 is shown. Extension unit 76 can comprise pin block holder 92, which can abut central unit 74. Bracket plate 94 can then be inserted in grooves disposed on top of pin block holder 92 and into corresponding grooves on the top of central unit 74. Threaded fasteners 90 can then be used to pass through openings disposed on top of bracket plate 94 into corresponding threaded holes in central unit 74 and pin block holder 92 to hold the elements together. In yet a further embodiment, end bracket 96 can be also installed on the end of pin block holder 92 underneath bracket plate 94 and held in place by a fastener 90. In some embodiments, fasteners 90 can comprise screws, bolts, socket head screws, thumb screws, threaded knobs, bayonet connectors, or any other functionally equivalent fasteners as well known to those skilled in the art.
Although a few embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention. The terms and expressions used in the preceding specification have been used herein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the invention is defined and limited only by the claims that follow.
Patent Application
20110068310
