Patent Application
20110072947
1. The Field of the Invention
The present invention generally relates to construction tools. More particularly, the present invention relates to a device for creating holes in construction materials.
2. The Relevant Technology
Metal decking is an important component in modern construction. It may be used to provide roofing or flooring in structures such as airports, universities, hospitals, and other large commercial buildings. Metal decking is often used in conjunction with concrete to provide a floor base. In fact, metal decking can be used to form multiple levels within a building, even when not used in conjunction with concrete. Additionally, the use of concrete and metal decking is spreading from large commercial settings to a more broad use including smaller buildings and even single-family homes.
After metal decking has been laid, there is often a need to produce holes in the decking. For example, plumbing, duct work, wiring or other material may need to be installed after the metal decking is in place. However, it can be difficult to make holes in the decking to allow access for these components. The current method for producing holes in metal decking is physically taxing and labor-intensive. To produce the desired holes, a device comprising a long external metal guide is held by one worker and an internal metal rod is moved up and down through the external guide by a second worker. In many cases, the internal rod is driven into the metal decking using a sledge hammer or through other means involving manual labor. The internal rod has a shaped point at the bottom end that is driven into the metal decking in order to produce a desired hole of the proper shape and size in the decking. The internal rod may have to be driven into the metal decking repeatedly before a hole is punched through the metal decking.
The above described method of punching holes in metal decking may be physically strenuous, and must be repeated for every hole made in the metal decking. Additionally, it may require the time and attention of two workers. This may be labor-intensive and very taxing on a construction crew. Additionally, there is potential for serious injury or damage to the structure. Thus, there is a need in the art for an improved means for punching holes in metal decking that would only require a single worker to operate. Also, there is a need for a less physically demanding means for producing holes in metal decking.
The subject matter claimed herein is not limited to embodiments that solve any disadvantages or that operate only in environments such as those described above. Rather, this background is only provided to illustrate one exemplary technology area where some embodiments described herein may be practiced.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
In light of the aforementioned needs, the present invention provides an improved means for producing holes in construction material via a pneumatic punching device. The present invention is operable by a single individual, and requires minimal physical effort in comparison to the current methods of producing holes within construction material.
In one exemplary embodiment of the invention, the device includes an outer housing. The outer housing includes an internal cavity, at least one opening and a distal end. The distal end is configured to be near the construction material during use. The device also includes an internal piston that includes a tip. The internal piston is received at least partially within the internal cavity and is configured for reciprocal motion within the outer housing. The device further includes a handle coupled to the outer housing and a trigger mechanism. The trigger mechanism is configured to release pressurized gas within a blast chamber. The pressurized gas drives the internal piston through the opening in the outer housing to produce a hole in the construction material.
In another exemplary embodiment of the present invention, the device includes an outer housing. The outer housing includes an internal cavity and at least one opening. The device also includes an internal piston with a tip. The internal piston is received at least partially within the internal cavity of the outer housing and the internal piston includes a longitudinal axis which is generally parallel to a longitudinal axis of the outer housing. The device further includes means for retracting the internal piston and means for regulating the motion of the internal piston within a desired range. The device also includes a handle coupled to the outer housing and means for driving the internal piston.
In another exemplary embodiment of the present invention, the device includes an outer housing. The outer housing includes an internal cavity, at least one opening, a first housing stop and a second housing stop. The device also includes an internal piston. The internal piston is housed at least partially within the internal cavity and is configured for reciprocal motion within the outer housing. The internal piston includes a first end, a second end with a tip opposite the first end and a first piston stop. The device further includes a means for retracting the internal piston. The means for retracting the piston retracts at least a portion of the internal piston through the opening into the internal cavity. The first piston stop is disposed between the first housing stop and second housing stop to work cooperatively with the first housing stop and second housing stop to regulate the reciprocal motion of the internal piston. The device also includes a handle which is coupled to the outer housing and a trigger mechanism attached to the handle. The device further includes a blast chamber. The first end of the internal piston is seated within the blast chamber and is able to move reciprocally therein. The device also includes a mechanism for driving the internal piston so the tip can punch a hole in the construction material. The mechanism for driving the internal piston can include a combustible powder, a gas compressor, a cartridge filled with compressed carbon dioxide, combinations thereof, and the like. For instance, a combustible powder can deposited within the blast chamber. The combustible powder can be detonated within the blast chamber when the trigger mechanism is actuated, driving the internal piston through the opening in the outer housing to produce a hole in the construction material. Similarly, a gas compressor or a cartridge filled with compressed carbon dioxide can be operatively associated with the blast chamber. When the trigger mechanism is actuated, the compressed gas from the compressor or cartridge can be released into the blast chamber, thereby driving the internal piston as described above.
Additional features and advantages will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the teachings herein. Features and advantages of the invention may be realized and obtained by means of the instruments and combinations particularly pointed out in the appended claims. Features of the present invention will become more fully apparent from the following description and appended claims, or may be learned by the practice of the invention as set forth hereinafter.
To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
The embodiments described herein extend to methods, devices, systems, assemblies, and apparatus for producing holes in construction materials, such as metal decking. Such methods, devices, systems, assemblies, and apparatus are configured to, for example, allow a single worker to quickly and accurately form a hole in a construction material without requiring excessive effort or physical force on the part of the worker.
Reference will now be made to the drawings to describe various aspects of exemplary embodiments of the invention. It is understood that the drawings are diagrammatic and schematic representations of such exemplary embodiments, and are not limiting of the present invention, nor are any particular elements to be considered essential for all embodiments or that elements be assembled or manufactured in any particular order or manner. No inference should, therefore, be drawn from the drawings as to the necessity of any element. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. It will be obvious, however, to one of ordinary skill in the art that the present invention may be practiced without these specific details. In other cases, well known aspects of construction tools and general manufacturing techniques are not described in detail herein in order to avoid unnecessarily obscuring the novel aspects of the present invention.
Throughout the application, the terms proximal and distal are used in the description of different ends of the device. Unless stated otherwise, the proximal end is towards the handle and the distal end is towards the tip. Additionally, the terms first and second are used in the description of different ends of the device. Unless stated otherwise, the first end corresponds to the proximal end and the second end refers to the distal end.
In at least one implementation, the internal piston 110 can be configured for reciprocal motion within the internal cavity and along the longitudinal axis of the internal piston 110. That is, the internal piston 110 can be configured to move back and forth within the internal cavity. Accordingly, the internal piston 110 can be driven through the internal cavity such that a portion of the internal piston 110 extends out of the opening in the outer housing 105 to produce a hole in the construction material. The internal piston 110 can then be partially or completely withdrawn back into the internal cavity, as discussed below.
In at lest one implementation, the arms 122a, 122b of the handle 120 may be relatively short in length, extending only far enough from a central post 123 for the operator to grip the handle 120. In particular, the arms 122a, 122b can be relatively short in length to provide access to areas, such as corners, where the operator has to operate in a relatively small area. Additionally or alternatively, the arms 122a, 122b of the handle 120 extending from the central post 123 may be longer. Longer arms 122a, 122b can provide greater stability or create a better grip for the operator.
In at least one implementation, the handle 120 can include a central post 123 extending distally from the handle 120 between the two arms 122a, 122b. In particular, the central post 123 can share a central longitudinal axis with the internal piston 110 and the outer housing 105. Additionally or alternatively, the central post 123 can be used to couple the handle 120 to the outer housing 105, to the internal piston 110, or both.
In at least one implementation, the trigger mechanism 125 can use a trigger mechanism 125 similar to trigger mechanisms used in firearms, as discussed below. Additionally or alternatively, the trigger mechanism 125 can include a button, a switch, a lever, a key or any other mechanism configured to release a compressed gas when activated by an operator. For example, the trigger mechanism 125 can include a button operably connected to an electronic device, such that the compressed gas is released into the blast chamber, as described below.
In at least one implementation, the safety lever 135 can be attached to the handle 120. For example, the safety lever 135 can be attached to the arm 122a, 122b of the handle 120 opposite the trigger mechanism 125. Additionally or alternatively, the safety lever 135 can be attached to the same arm 122a, 122b of the handle 120 as the trigger mechanism 125. Alternatively, the safety lever 135 can be attached to the central post 123 of the handle 120. Further, the safety lever 135 can be attached to the one or more footholds 140, discussed below.
In at least one implementation, the one or more footholds 140 are not permanently attached to the outer housing 105. For example, the one or more footholds 140 can be adjustable, such that their location and orientation relative to the outer housing 105 can be adjusted. Additionally or alternatively, the one or more footholds 140 can be removably attached to the outer housing 105, such that the one or more footholds 140 can be removed as desired by the user.
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In at least one implementation, the coupling between the handle 120 and the outer housing 105 can be a rigid attachment such that no movement is observed between the handle 120 and the outer housing 105. Additionally or alternatively, the handle 120 is able to disengage from the outer housing 105, which may be useful in depositing additional sources of compressed gas in the blast chamber 230, as discussed below. Additionally or alternatively, the coupling can be configured such that the handle 120 is able to rotate about the shared central axis at the interface relative to the outer housing 105. The rotation of the handle 120 relative to the outer housing 105 can provide rotation of the tip 115. The rotation of the handle 120 relative to the outer housing 105 can also provide a means of “cocking” the device, as described below.
Additionally or alternatively, the measuring mechanism 150 can include a window placed within the handle 120 with markings designating different angles such that as the central post 123 of the handle 120 is rotated, a component beneath the window remains stationary and the degree of rotation can be measured by viewing how far the window has moved in relation to the stationary component. Additionally or alternatively the measuring mechanism 150 can include a window placed on the outer housing 105 with markings designating varied angles such that as the internal piston 110 is rotated, a component of the internal piston 110 is viewable through the window to measure how far the internal piston 110 has rotated.
In at least one implementation, the means for retracting 210 the internal piston 110 can include a damping mechanism. In particular, damping is any effect that tends to reduce the amplitude of oscillations in a system which has the ability to oscillate. A system is considered critically damped if the system returns to equilibrium as quickly as possible without oscillating. A system is considered over damped if the system returns to equilibrium without oscillating, although the system returns to equilibrium more slowly than a critically damped system. The more the system is over damped, the slower the system returns to equilibrium. A system is considered under damped if the system oscillates with the amplitude gradually decreasing to zero.
In at least one implementation, the compressed gas can be produced using a combustible or explosive material. A combustible material can include a material that is capable of burning or is otherwise involved in an exothermic process. An explosive material is a material that either is chemically or otherwise energetically unstable or produces a sudden expansion of the material usually accompanied by the production of heat and large changes in pressure upon initiation. An explosion can proceed through deflagration or through detonation. Deflagration includes subsonic combustion that propagates through thermal conductivity. That is, hot burning material heats the next layer of cold material and ignites it, propagating through the material. In contrast, detonation can include combustion in which a supersonic shock wave (or pressure wave) is propagated through a material. The shock compresses the material thus increasing the temperature of the material to the point of ignition. The ignited material burns behind the shock and releases energy that supports the shock propagation.
In at least one implementation, the compressed gas can be produced in the blast chamber 230 through the ignition of gunpowder or another propellant powder. In particular, a combustible powder can be placed directly within the blast chamber 230. Additionally or alternatively, the combustible material can be placed in a container 240 such as a bullet, a shell, a casing or any other suitable container which is configured to be contain a known amount of combustible material and placed within the blast chamber 230.
In at least one implementation, the container 240 can be stored within a storage device such as a clip, a round, a cartridge or any other device which is configured to store multiple containers 240. In particular, the storage device can be configured to load a second container 240 in the blast chamber 230 upon the removal of a first container 240. For example, the second container 240 can be placed in the blast chamber 230 through pump action, bolt action, lever action, a semi-automatic or an automatic action.
A pump-action includes a mechanism in which a handgrip or other pumping can be pumped back and forth in order to eject a spent container 240 and place a fresh one within the blast chamber 230. A bolt action includes a mechanism in which a bolt is operated manually to open and close the blast chamber 230. As the bolt is operated the blast chamber 230 is opened, the spent container 240 is withdrawn and ejected, and a new container 240 is placed into the blast chamber 230 and the bolt is closed. A lever-action includes a lever, which can be located around the trigger guard area or include the trigger guard 130 itself, that can be moved one direction to open the blast chamber 230 and eject a spent container 240. The lever can be subsequently moved back to its initial location to insert a new container 240 in the blast chamber 230 and close the blast chamber 230. A semi-automatic system includes a mechanism that uses the force of the deflagration or detonation to eject the spent container 240, load a new container 240 and prepare the trigger mechanism 125 to fire again when the trigger mechanism 125 is released and reactivated. In contrast, an automatic system is similar to a semi-automatic system, however, the trigger mechanism 125 does not need to be released and reactivated for subsequent firings.
It will be appreciated that other drive mechanisms in addition to those described above can be used without departing from the scope of the present invention. For instance, the punch device 100 may be formed with, or attached to, a gas compressor 160 that compresses air or other gases. The compressed gas can be communicated from the gas compressor 160 to the blast chamber 230 via hosing 162. More specifically, when trigger mechanism 125 is actuated, a valve can be opened that allowed the compressed gas from gas compressor 160 to enter into the blast chamber 230. Introduction of the compressed gas into the blast chamber 230 can drive the internal piston 110 in a similar manner as described above.
In still other exemplary embodiments, compressed carbon dioxide (CO2) can be used to drive the internal piston 110. Compressed carbon dioxide can be stored in containers 240 that can be loaded into the blast chamber 230, or otherwise associated with blast chamber 230. When the trigger mechanism 125 is actuated, the container 240 can be punctured (e.g., with firing pin 250), thereby releasing the compressed carbon dioxide. The release of the compressed carbon dioxide can drive the internal piston 110 in order to form a hole in the construction material.
In light of the disclosure herein, it will be appreciated that the internal piston can be driven using any one of a number of pneumatic mechanisms. Furthermore, it will be understood that the above described mechanisms (e.g., combustible materials, a blast chamber, a compressed gas such as air and/or compress carbon dioxide, gas compressors, and the like) are each examples of means for driving the internal piston 110.
Additionally or alternatively, a cocking action can be used in combination with a pump-action, bolt-action or lever-action to remove a spent container 240 from the blast chamber 230 and load an additional container 240. For example, the cocking action can be provided by rotating the handle 120 relative to the outer housing 105. As the handle 120 is rotated in one direction, the spent container 240 is removed from the blast chamber 230. As the handle 120 is rotated back to the original position a fresh container 240 from the clip, round, or cartridge is deposited within the blast chamber 230. Additionally or alternatively, an external lever or bolt can be operably attached to the blast chamber 230 to allow the removal of the spent container 240 and the deposit of another container 240 into the blast chamber 230.
The present invention is described in terms of using the device in the context of metal decking; however, it will be appreciated that the present invention can be used in a variety of situations to punch holes in a variety of materials. For example, the device can be used to punch holes in wood flooring, concrete, other sheets of metal, and the like. Further, the device has been described as punching a hole in construction material with a single use of the device; however, it is within the scope of the device to be used in scenarios in which multiple uses of the device may be required to punch a hole in construction material.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
