The present disclosure relates to the field of hand tools, and specifically to a device for installing and manually driving a post into a substrate, such as the ground.
When installing posts, stakes, poles, and similar elongated structures (collectively, “posts”), such structures typically need to be driven into a substrate to a depth sufficient to ensure stable placement. Generally, the deeper a post is driven into the substrate, the more stable it will be. Harder and/or denser substrates such as day and soil, while potentially offering greater support (and thus, stability) compared to softer substrates such as sand and gravel, pose a greater resistance into driving the post to the necessary depth. Where a substrate offers substantial resistance, the installer may turn to mechanical assistance to achieve the necessary depth. For smaller posts, such as rods or stages, a mallet (typically weighing a few pounds at most) may provide sufficient mass and driving power. For larger posts, a post pounder may be employed, which can be manually driven or powered. Manual post pounders typically weigh over 10 pounds for basic small models, and are available in increasing weights to accommodate larger posts. Manual post pounders are typically manipulated by hand for positioning, with the mass of the post pounder in conjunction with gravity helping to provide the driving force. A post pounder with sufficient mass can be effective at driving comparatively larger posts through dense substrates.
Embodiments will be readily understood by the following detailed description in conjunction with the accompanying drawings. Embodiments are illustrated by way of example and not by way of limitation in the figures of the accompanying drawings.
In the following detailed description, reference is made to the accompanying figures which form a part hereof, and in which are shown by way of illustration embodiments that may be practiced. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope. Therefore, the following detailed description is not to be taken in a limiting sense, and the scope of embodiments is defined by the appended claims and their equivalents.
Various operations may be described as multiple discrete operations in turn, in a manner that may be helpful in understanding embodiments; however, the order of description should not be construed to imply that these operations are order dependent.
The description may use perspective-based descriptions such as up/down, back/front, and top/bottom. Such descriptions are merely used to facilitate the discussion and are not intended to restrict the application of disclosed embodiments.
The terms “coupled” and “connected,” along with their derivatives, may be used. It should be understood that these terms are not intended as synonyms for each other. Rather, in particular embodiments, “connected” may be used to indicate that two or more elements are in direct physical contact with each other. “Coupled” may mean that two or more elements are in direct physical contact. However, “coupled” may also mean that two or more elements are not in direct contact with each other, but yet still cooperate or interact with each other.
For the purposes of the description, a phrase in the form “A/B” or in the form “A and/or B” means (A), (B), or (A and B). For the purposes of the description, a phrase in the form “at least one of A, B, and C” means (A), (B), (C), (A and B), (A and C), (B and C), or (A, B and C). For the purposes of the description, a phrase in the form “(A)B” means (B) or (AB) that is, A is an optional element.
The description may use the terms “embodiment” or “embodiments,” which may each refer to one or more of the same or different embodiments. Furthermore, the terms “comprising,” “including,” “having,” and the like, as used with respect to embodiments, are synonymous.
Manual post pounders are typically implemented as hand tools. A manual, or hand-driven, post pounder is essentially a hollow tube equipped with a pair of handles that extend from the tube sides in an opposing fashion. In a common configuration, the tube is open at one end, and sealed at the opposing end. The tube and/or handles may be weighted to achieve a desired mass to facilitate driving posts. In use, the post driver is first placed over the top of a post to be driven. The top portion of the post inserts into the hollow tube via the open end. Holding onto each handle, the user then repeatedly lifts the post pounder, and forcibly brings it down upon the post. The sealed end of the tube thereby strikes the top of the post, and so imparts energy from the momentum of the post driver to the post, repeatedly driving the post into the substrate. By keeping the post within the hollow tube, the blows from the post pounder are focused upon the top of the post and imparted in a direction substantially along the longitudinal axis of the post. The diameter of the hollow tube determines the maximum size of post that can be driven by a given post pounder, while the mass of the post pounder determines how hard a substrate into which the post pounder can drive a post (provided the post can absorb the blows without excessive deformation), with higher mass post pounders capable of delivering more powerful blows and so driving into denser substrates.
Each handle of a currently available typical post pounder is attached to the side of the tubular body of the pounder at two attachment points, spaced apart longitudinally. The handles are typically disposed on the body so as to oppose each other, e.g. each handle is positioned 180 degrees from the other where the body is substantially circular in cross-section, or on opposed sides where the body is square in cross-section. Each handle typically has a main portion that runs substantially parallel to the longitudinal axis of the post pounder, but spaced apart from the body a distance at least sufficient to accommodate the fingers of a user. Other currently available post pounders may slightly angle the main portion of each handle relative to the longitudinal axis, so that each handle is spaced further from the body at one attachment point compared to the other attachment point. In either implementation, the pair of handles typically provides a relatively narrow grip, which may not provide optimal ergonomics. As a result, the grip may cause relatively rapid operator fatigue in use, due to poor use of chest and/or arm muscles. The onset of fatigue, in turn, reduces potential productivity of the operator, especially in settings where multiple posts must be driven. Further still, the narrow grip may render the post pounder awkward to use where the post is relatively short or tall relative to the operator, due to the operator being forced into unusual angles. Finally, particularly where the pair of handles are oriented substantially parallel to the sides of the body, the operator's grip may be prone to slipping during use, reducing controllability and potentially reducing the force of impact that the operator may be able to impart with the pounder.
In another aspect, the closed end of the hollow tube is an impact surface, which acts as the interface where energy is imparted from the post pounder to the post being driven. As such, it bears the majority of wear, and is subject to the greatest stresses while in use. Existing post pounders are typically constructed from a hollow tube, with a plug or cap affixed to one end of the tube to close it and form the impact surface. The handles may be welded or otherwise attached to the exterior side of the tube. The nature by which the plug or cap is attached to the tube can impact the longevity and performance of the post pounder. For example, caps that are press-fit may not be capable of withstanding the same level of force as a cap that is welded in place. Even with a cap that is welded in place and is of a relatively substantial thickness, the weld may only penetrate a fraction of an inch, with the weld depth ultimately defining the longevity of the post pounder, as the weld is required to absorb the full force of each impact. With use over time, the weld or other attachment means that secures the plug or other attachment means in place may weaken and ultimately fail. If the attachment means fails, the end plug may become dislodged, allowing the post to pass entirely through the post pounder, rendering the post pounder useless.
Embodiments disclosed herein provide a post pounder that offers a grip with improved ergonomics, and/or reinforces the end plug or closing means by use of the handle structure. Disclosed embodiments form the handle from a single bar, rod, or shaft, which is attached at one end on a side of the hollow body, passed over the closed end of the body, and secured at a second end on the opposing side of the hollow body. By passing the bar over the closed end, the bar acts as a reinforcing structure to retain the plug or other closing means with a greater strength than is possible if the plug or closing means is simply welded or otherwise attached with another attachment means to the body. Further, the bar may be shaped into an approximately delta shape, with the handles angled away from the body. The angled handles offer a wider, more ergonomic grip that can decrease slippage, offering an operator a more comfortable grip that potentially yields better use of chest and arm muscles. This delta geometry thus results in less fatigue to the operator, potentially an improved imparting of impact force, and easier/more comfortable use of the post pounder on posts of widely varying heights. Consequently, operator productivity can be enhanced.
Body 102, in embodiments, is constructed from an elongated tube, such as a pipe. Body 102 may have a round or substantially circular cross-section, a polygonal cross-section, e.g. triangular, square, pentagonal, hexagonal, etc., or a cross-section of an arbitrary shape, as may be appropriate for an intended use of the post pounder 100. As will be understood, the size of body 102 at least partially determines the sorts of materials with which a given embodiment of a post pounder 100 may be used. The wall of body 102 may be of a suitable thickness to obtain a desired durability and overall weight. Further, body 102 may be constructed from a material that is suitably durable for a given use. In some embodiments, body 102 may be constructed from a durable metal, such as iron or steel, or another suitable alloy, or another suitable material such as a plastic or a composite. As with the wall thickness, the wall material may be selected to obtain a desired weight, with the material and thickness of the wall of body 102 being the primary factors in determining the overall weight of post pounder 100. In other embodiments, post pounder 100 may be fitted with material specifically to achieve a desired weight. It will be understood that a heavier post pounder 100 may be able to impart more forceful blows upon a post being driven, at the expense of requiring a greater exertion by the user.
Body 102, defining a longitudinal axis, includes a first end 104 and a second end 106, distally located from first end 104. The length of body 102, defined as the distance between first end 104 and second end 106, may be selected with respect to the intended use of post pounder 100. In some embodiments, the length of body 102 is sufficient to allow a typical user to effect sufficiently powerful blows against a post to be driven without having to lift the post pounder 100 fully above the post being driven (where second end 106 clears the post being driven), e.g. at all times during use, a portion of the post being driven is enclosed within body 102.
First end 104 may include a plug 120 or other closing means, while second end 106 is open to allow access to interior space 108, for insertion of a post or pole to be driven by post pounder 100. Plug 120, in embodiments, comprises the primary impact surface of post pounder 100, which directly imparts the force of blows to a post that is being driven. Plug 120 may be constructed from a plate of similar thickness and material as the wall of body 102, e.g. a steel plate, or may be constructed of a different material, or material of a different thickness, as may be appropriate for a given use of post pounder 100. In some embodiments, plug 120 may be thicker or otherwise reinforced to withstand absorbing the repeated blows imparted while post pounder 100 is in use. Further, plug 120 may be used to help achieve a desired weight of post pounder 100.
Plug 120 may be secured to first end 104 of body 102, in some embodiments, using a suitable technique such as welding, brazing, soldering, press-fitting, or any other technique that secures plug 120 so that it can withstand impacts to a post being driven as well as transfer the energy of each impact from the post pounder 100 to the post. In other embodiments, plug 120 may be formed as an integral part of body 102. Plug 120, in embodiments, is further secured via rod 112, as will be discussed herein. In still further embodiments, plug 120 may be omitted, and rod 112 may form the primary impact surface of post pounder 100. Still further, plug 120 may be formed integral with rod 112.
An example embodiment of a plug 120 is depicted in
Attached to either side of body 102, in the depicted embodiment, are handles 110a and 110b (non-specifically referred to as handle 110). Each handle 110a and 110b includes a respective bend 122a and 122b (non-specifically referred to as bend 122), so as to divide each handle 110 into two segments separated by an angle, with each bend 122 forming a point at which each handle 110 is furthest away from body 102. As a result, each handle 110, in embodiments, provides two differently angled gripping surfaces, which further can be gripped near to the body 102 when gripped near either first end 104 or second end 106, or further from the body 102 when gripped near bend 122. This varying spacing allows users of different sizes to readily find a gripping distance that feels natural, allowing for extend use of the post pounder 100 without significant fatigue. Further, the presence of bend 122 results in each portion angling away from body 102, presenting a handle angle that is more ergonomic to grip, e.g. more closely follows the natural gripping angle of a user, whether gripped overhand or underhand. Post pounder 100 can thus be gripped with either an overhand grip by grabbing the section of each handle 110a and 110b that is proximate to first end 104, or an underhand grip by grabbing the section of each handle 110a and 110b that is proximate to second end 106. As will be understood, the relative angles of each handle section can be varied by changing the location of bend 122 along the longitudinal axis of body 102, e.g. moving it more proximate to either first end 104 or second end 106, while keeping the distance of bend 122 to body 102 constant. Alternatively, the angles of each section can be altered by varying the distance of bend 122 to body 102 while keeping the longitudinal location of bend 122 fixed.
Handles 110a and 110b, as can be seen, are formed from a single rod 112, in some embodiments. In such embodiments, rod 112 is attached to body 102 at the first point 114 and second point 116, and is formed by creating bends 122a and 122b, as well as by passing rod 112 closely over first end 104. Thus, a portion 118 of rod 112 is passed over plug 120, thus providing structural reinforcement for the plug 120, in addition or alternatively to how plug 120 may be attached to body 102, described above. Portion 118 can thus act to absorb at least a portion of each impact imparted by post pounder 100, and/or reinforce the attachment of plug 120 to body 102. In some embodiments, plug 120 may be secured to portion 118, such as by welding, brazing, soldering, or another suitable attachment technique. When so secured to portion 118, plug 120 may not need to be secured or attached to body 102, with rod 112 acting to hold plug 120 in place and absorb impacts from use of the post pounder 100. In some embodiments, handles 110a and 110b may be formed from a plurality of separate pieces that may be subsequently joined, such as by welding, soldering, brazing, or another suitable joining technique.
Referring to
As can also be seen in
Turning to
In distinction from post pounder 100, the rod 512 is bent and shaped to orient each handle 510 in a relatively more parallel fashion relative to body 502, albeit with a slight angle in the depicted embodiment. The bends closest to the second end 506 approach 90 degrees, to form second handles 522a and 522b (generically, 522) that extend nearly perpendicular away from body 502. In this configuration, each handle 522 can be readily gripped either overhand or underhand, depending upon the user's preference. The orientation of handles 522 may vary depending upon the needs of a given embodiment. While in the depicted embodiment handles 522 are angled slightly towards the first end 504 and away from second end 506, in some embodiments, handles 522 may be oriented slightly towards second end 506, and away from first end 504. As will be understood, such configurations may be achieved by altering the angle at which rod 512 is bent to form handles 510 and handles 522.
Rod 512 also is bent to form handles 510 further away from first end 504 as compared to post pounder 100. This greater distance allows for the formation of third handles 514a and 514b (generically, 514). In the depicted embodiment, handles 514 extend perpendicular away from the longitudinal axis of body 502. Other embodiments may angle handles 514 towards or away from body 502, such as by curving or bending the portion of rod 512 that runs across the first end 504. Handles 514 provide an additional position to be gripped either overhand or underhand. The formation of handles 514 can facilitate use of post pounder 500 for driving relatively low-height posts (e.g. below an operator's waist) by allowing post pounder 500 to be manipulated from its top. In such a position, a user would otherwise likely have to crouch, bend over, or sit to use post pounder 500 with handles 510, which could lead to discomfort at best, and possibly injury. Further, the provision of handles 514 at the top of post pounder 500 allows post pounder 500 to be manipulated with the bulk of its weight suspended below the handles 514, which some users may find easier, depending upon the weight of post pounder 500.
As can be seen in
Weight 508, in embodiments, may be constructed from the same materials as body 502. In other embodiments, weight 508 may be constructed from a different material, such as a material selected to achieve a desired weight and balance for post pounder. Possible materials may include steel, aluminum, lead, copper, titanium, or another suitable metal, ceramic, concrete, plastic, or any other suitable material.
Although certain embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a wide variety of alternate and/or equivalent embodiments or implementations calculated to achieve the same purposes may be substituted for the embodiments shown and described without departing from the scope. Those with skill in the art will readily appreciate that embodiments may be implemented in a very wide variety of ways.
This application is intended to cover any adaptations or variations of the embodiments discussed herein. Therefore, it is manifestly intended that embodiments be limited only by the claims and the equivalents thereof.
This application claims the priority benefit of the earlier filing date of U.S. Provisional Application No. 62/886,955, filed Aug. 14, 2019, which is hereby incorporated herein by reference in its entirety.
Number | Date | Country | |
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62886955 | Aug 2019 | US |