Patent Application
20120145764
This application relates generally to an installation device and system that supports and drives a fastener, such as a spike, into a solid object, such as a roadway. More specifically, this application relates to an installation device that surrounds and guides a fastener while it is driven into the surface of a solid object.
Spikes, stakes, nails, large staples, and other such fasteners can be used to secure together large, objects, such as metal, wood, asphalt, etc. For instance, spikes are commonly driven into railroad ties to secure rails and tie plates to the tie. Additionally, spikes are commonly driven into asphalt roads to secure steel traffic plates in place on a roadway surface. Traditionally, spikes have been driven into target objects using a sledge hammer that is manually hefted by a user.
This application describes an installation device for installing a fastener into a solid object, such as a roadway. Generally, the installation device can be made of a sleeve and a rod with a power hammer connector on a proximal portion of the rod. The sleeve can have an inner bore having an inner volume configured to receive a fastener. The rod can be selectively inserted within the inner bore of the sleeve. The distal end of the rod can have a substantially flat surface. The distal end of the rod can be magnetized to attract and hold a fastener thereon. The installation device enhances containment of the spike during installation, which can significantly reduce damage and injuries resulting from fly-away fasteners.
The following description can be better understood in light of the Figures, in which:
The Figures illustrate specific aspects of the installation device comprising an installation device and methods for installing a fastener with the installation device. Together with the following description, the Figures demonstrate and explain the principles of the structure and methods of this device. The same reference numerals in different drawings represent the same element, and thus their descriptions will not be repeated.
The following description supplies specific details in order to provide a detailed understanding of the Figures. Nevertheless, the skilled artisan would understand the installation devices and methods for using these devices could be implemented and used without employing these specific details. Indeed, the installation devices and associated methods can be placed into practice by modifying the illustrated devices and methods and can be used in conjunction with any other apparatus and techniques conventionally used in the industry. For example, while description refers to installation devices for driving spikes into a roadway, it could be modified and used for fasteners other than spikes, such as spikes, stakes, nails, large staples, magnetic spikes, steel rebar, and solid objects other than roadways, such as concrete, stone, dirt, clay, wood, metal, etc.
Some embodiments of the installation devices and methods for using such devices are described herein and illustrated in the Figures. In this Figures, the term proximal refers to a part of the device or component near the user while the term distal refers to a part of the device or component away from the user. The installation devices contain an impact device (such as a power hammer) that drives a fastener (such as a spike) into a solid object (such as blacktop or asphalt surface). In some embodiments, the fastener can be used to attach an attachment member (such as a metal plate) to the solid object. Other representative attachment members include railroad ties, façade supports, and the like.
The installation device can work with any suitable impact device known in the art, such as power hammers, pistons, or impact guns. The impact devices repeatedly produce an impact force on the fastener, thereby driving it into the solid object. As well, the installation device can also stabilize the fastener during this process. The installation device can be used to drive the selected fastener into any solid object. Representative solid objects include roadways, wood, concrete, metal, rock, etc. The installation device can be utilized with any suitable fastener known in the art. Examples of suitable fasteners include spikes, stakes, nails, large staples, magnetic spikes, rods, or rebar.
In some embodiments, the impact device comprises a power hammer and the fastener includes a spike. These embodiments are illustrated in
As shown in
The installation device 10 can prevent injuries by enabling the use of power hammers 12. Power hammers 12, such as a pneumatic drill/hammer (or jackhammer) or impact gun, can be powered by electricity, compressed air, hydraulics, etc. and can reduce the manual force required to install the spike 14. Using the power hammers avoids the used manual sledge hammers, reducing the number of soft tissue injuries that might otherwise occur during spike installation.
In use, as illustrated in
Referring now to the specific parts illustrated in
The rod 24 can be inserted within the inner bore of the sleeve. The distal end of the rod can have a substantially flat surface. The rod 24 is an elongated body member, such as a bar. In some embodiments, the rod 24 is a solid rod, such as a solid metal rod. The rod 24 can be manufactures of a variety of materials configured to withstand repeated pounding. Representative materials include steel, iron, etc.
The proximal end portion of the rod 24 can connects the rod to the impact device. In some embodiments, the rod 24 can be coupled to a power hammer 12 via connector 28 that is disposed on a proximal portion of the rod, such as the proximal 0% -15% of the rod's length. The connector 28 is a feature or component of the rod used to connect to an impact device. The impact device connector 28 can have a variety of shapes, sizes, and configurations, based on the shape and size of the rod and the type of impact device 12 used. This impact device connector 28 can be as simple as a flat surface on a cylindrically-shaped rod 24, or a hole (not shown) through the rod 24. Alternatively, in some embodiments, this impact device connector 28 is a set of shapes and surfaces that mate with the power hammer 12, such as the impact device connector 28 depicted in
The rod 24 extends distally from the power hammer connector 28 for a length that is greater than or substantially equal to the length of a spike. In some embodiments, the rod's length is between about two and about forty inches. In other embodiments, the rod's length is less than about two inches or greater than about forty inches. In some embodiments, the rod's length is between about six and about twenty-four inches. In some embodiments, the rod's length is between about six and about eighteen inches.
The distal end of the rod 24 contacts the head 15 of the spike 14, transferring the downward force of the power hammer to the spike, driving it downward. Accordingly, the surface of the distal end of the rod 24 may have a shape that most effectively transfers this force. For example, in some embodiments, the distal rod surface is a single drive surface, having no edges, corners, or other junctures on the distal face of the rod. In some embodiments, this surface is substantially flat having only minor curvature. The substantially flat surface may have minor deviations from a perfect mathematical plane. For example, in some embodiments, it may be advantageous to provide some curvature on the distal end of the rod. For instance, in some embodiments, the substantially flat distal surface may includes a concave shape that mates with the top surface of the spike's head 15. Such a concave surface may be useful in maintaining the head of a spike in a proper placement relative to the rod and the inner bore.
In some embodiments, the distal end of the rod 24 is magnetized. This magnetizated end can attract a spike 14 and assist to retain the spike within the sleeve prior to the spike installment. Additionally, in some embodiments, the spike or other fastener is magnetized. In some embodiments both the distal end of the rod 24 and the fastener are magnetized.
In some embodiments, the sleeve 22 can be a hollow body having two ends, a distal end and a proximal end, and an inner bore 21 extending between these two ends. The sleeve may be, but is not necessarily, cylindrical. Rather, the sleeve, the rod, and the inner bore may be manufactured in a variety of shapes and sizes depending on the intended use of the installation device. Thus, in some embodiments, the sleeve, rod, and/or the inner bore have circular, elliptical, oval, square, or rectangular cross sections. For example,
The sleeve 22 can be retractably disposed around a portion of the rod 24. Accordingly, the sleeve, the inner bore, and the rod can a variety of sizes and dimensions. In some embodiments, the rod and inner bore have constant cross sectional areas along their lengths. In these embodiments, the cross sectional area of the inner is approximately equal to or great than cross sectional area of the rod 24. In other embodiments, the cross sectional areas of the rod and/or the inner bore can vary along their lengths. Similarly, the sleeve, the inner bore, and the rod can a variety of sizes and dimensions.
Generally, the inner bore can be shaped to house a spike. Accordingly, in some embodiments, in some embodiments, the inner bore has a length between two and forty inches. In other embodiments, the inner bore's length is less than about two inches or greater than about forty inches. In some embodiments, the inner bore's length is between about six and about twenty-four inches. In some embodiments, the inner bore's length is between about six and about eighteen inches. Additionally the inner bore may have a cross sectional area between about one and about thirty square inches. In other embodiments, the inner bore's cross sectional area is less than about one square inches or greater than about thirty square inches. In some embodiments, the inner bore's cross sectional area is between about three and about ten square inches. In some embodiments, the inner bore's cross sectional area is between about four and about eight square inches.
The sleeve 22 can disposed around a distal portion of the rod 24 with any suitable configuration when installed on the rod 24. Thus, in the embodiments illustrated in
A catch includes one or more features or components that limit the movement of the rod 24 through the sleeve 22 beyond a certain point, a catch point. For example, the catch may limit the rod's ability to be completely withdrawn from the sleeve. Alternatively, the catch may limit the ability of the distal end of the rod to be withdrawn past a catch point of the sleeve, such as one to three inches from the proximal end of the sleeve. The catch may limit the movement of the rod 22 through this catch point, in a variety of fashions. For example, in some embodiments, the catch requires a threshold force to be applied to the rod before it permits the rod 24 to continue moving beyond the catch point. In other embodiments, the catch includes a breakable, safety component that must be broken, thus limiting the movement until the safety component is broken. In still other embodiments, the catch completely limits the rod's movement past the catch point unless the rod is oriented to a predetermined orientation in relation to the sleeve. In yet other embodiments, the catch completely limits the rods movement past the catch point. Representative embodiments of catches and catch components are depicted in
In some embodiments, the rod 24 can contain a stop 26 disposed along its length. The stop is an outward projection extending away from a portion of the body of the rod 24. The shape and size of the stop prevents that portion of the rod from entering into the sleeve 22. In some embodiments, the stop 26 is integrally formed with the rod body. For example, in some embodiments, a stop 26 is a projection that is included on the rod body when the rod is manufactured. In other embodiments, the stop 26 is a separate component, such as a circlip (or circlip ring) 52, as shown in
Since the stop 26 can prevent that portion of the rod 24 from entering the sleeve 22, in some embodiments, the distance between the distal end of the rod and the stop 26 is greater than or equal to the length of the sleeve. These distances can enable the rod 24 to extend entirely into the sleeve 22 to drive a spike 14 completely into a surface. In other embodiments, the length of the rod is equal to length of the sleeve, such that the rod extends nearly, but not exactly to the end of the sleeve, to enable the spike to be driven into a surface, but allow the head 15 of the spike 14 to remain above the surface. These distances might be useful when securing rails and tie plates to the tie. In other embodiments, an adjustable stop can be included on the rod 24. For example, multiple non-permanent stops, such as that of
The first catch shown in
The second catch shown in
As shown in
The type of ring 52 used with the catches may vary the catch's ability to limit the rod's movement. For example, if a high-strength titanium ring is used, that is sized to have a very small gap 60, the catch may completely limit the rod's ability to move beyond the catch point. In other embodiments, a breakable ring may limit the rod's ability to move beyond the catch point until a sufficient force causes the breakable ring to break. In other embodiments, a flexible ring may limit the rod's ability to move beyond the catch point until a sufficient force causes the flexible ring to flex. In some embodiments, the ring 60 includes a circlip, as shown in detail in
In some embodiments, the width 84 of the opening created by the distal flange 42 is greater than or equal to the width 82 of the head 15 of a spike 14. These proportions permit the spike's head to enter and exit this opening.
In some embodiments, the groove 92 serves as a catch component along with an expandable ring 52, such as the circlip ring 52 (as shown in
In some embodiments, the groove 92 includes a sloped wall 94 on the opposite side of the groove 92 as the flat wall 96. This sloped wall 94 is the wall nearest the center of the sleeve 22. After the expandable ring 52 enters the groove 92 and expands, it may be withdrawn from the groove 92 as it is drawn toward the sloped wall 94. The angle of the sloped wall allows the expandable ring 52 to contract, which permits the expandable ring 52 to be contained within the inner portions of the sleeve.
The installation devices described herein can reduce the potential for injury when driving a spike with a sledge hammer. Without the guide sleeve, the sledge hammer might miss hit the spike and cause the spike to fly away. A flying spike may injure the person installing the spike, as well as buildings, passing vehicles, or pedestrians. The risk of these dangers can be heightened when spikes are installing in high traffic area, such as along roadways or sidewalks. Additionally, repeatedly hefting and swinging a sledge hammer can lead to soft tissue injuries. However, the installation device described herein can reduce or avoid these risks since it permits users to quickly and accurately install spikes without the risk of soft tissue injuries or flying spikes.
In addition to any previously indicated modifications, those skilled in the art may devise numerous other variations and alternative arrangements without departing from the spirit and scope of this description. The appended claims are intended to cover such modifications and arrangements. Thus, while the information has been described above with particularity and detail in connection with what is presently deemed to be the most practical and preferred aspects, it will be apparent to those of ordinary skill in the art that numerous modifications, including, but not limited to, form, function, manner of operation and use may be made without departing from the principles and concepts set forth herein. Also, as used herein, examples are meant to be illustrative only and should not be construed to be limiting in any manner.
