Patent Application
20240335055
The present disclosure relates generally to tools for installing carpet onto a floor and more particularly to a tool assembly for installing carpet between non-parallel walls a related method for making the same.
A successful carpet installation onto a floor typically requires the carpet to be evenly stretched across its length and width to avoid wavy areas. Many techniques have been used to stretch the carpet to achieve a tight profile across the entire floor. Typically a first side of the carpet is fixed to the floor such as to tack strips along a first wall. In some examples this first side of carpet can be additionally pulled toward the first wall with a supplemental tool such as a knee kicker tool or hinge arm tool. The process can be repeated around the remaining walls.
While such tools and techniques are generally adequate for installation on rooms that are square, properly stretching carpet during installation in rooms where opposite walls are not parallel poses challenges. For example, it can be difficult to adequately and evenly distribute the proper tension onto the carpet to minimize wavy areas.
The background description provided herein is for the purpose of generally presenting the context of the disclosure. Work of the presently named inventors, to the extent it is described in this background section, as well as aspects of the description that may not otherwise qualify as prior art at the time of filing, are neither expressly nor impliedly admitted as prior art against the present disclosure.
SUMMARY
A carpet installation tool assembly configured to stretch carpet between two non-parallel walls is provided. The carpet installation tool assembly comprises a first leg positioning assembly, a second leg positioning assembly, a central frame member, and a hinge arm tool. The first leg positioning assembly includes a first tube support assembly having a first tube and a second tube, wherein one of the first and second tubes moves axially relative to the other of the first and second tubes during a locating step. A first angled wall engaging assembly is pivotally coupled to the first tube support assembly and is configured to engage the angled wall during a carpet stretching event. The second leg positioning assembly includes a second tube support assembly having a third tube and a fourth tube, wherein one of the third and fourth tubes moves axially relative to the other of the third and fourth tubes during a locating step.
A second angled wall engaging assembly is pivotally coupled to the second tube support assembly and that is configured to engage the angled wall during a carpet stretching event. The first and second leg positioning assemblies are selectively coupled to the central frame member. The hinge arm tool includes a pivot arm, a foot and a carpet pad. The foot is arranged at a first end and positions against the central frame member and a carpet pad arranged at an opposite end that engages carpet near the straight wall. The hinge arm tool has a telescoping leg assembly that creates opposing forces onto the central frame member and the carpet pad upon actuation of the pivot arm. Actuation of the pivot arm creates (i) a plurality of first carpet forces along and toward the angled wall proximate the first and second angled wall engaging assembly and (ii) a plurality of second carpet forces along and toward the straight wall proximate the carpet pad thereby distributing a carpet stretching action across the carpet between the angled and straight walls.
In additional examples, the carpet installation tool assembly includes a first torque applying assembly having a first end selectively coupled to the central frame and a second end selectively coupled to the first angled wall engaging assembly, the first torque applying assembly applying tension between the central frame and the first angled wall engaging assembly urging a rotating action of the first angled wall engaging assembly into the angled wall.
In additional examples, the carpet installation tool assembly includes a second torque applying assembly having a first end selectively coupled to the central frame and a second end selectively coupled to the second angled wall engaging assembly, the second torque applying assembly applying tension between the central frame and the second angled wall engaging assembly urging a rotating action of the second angled wall engaging assembly into the angled wall.
In examples, the first tube support assembly further comprises a first locking collar that selectively locks the first and second tubes from axially moving relative to each other. The second tube support assembly further comprises a second locking collar that selectively locks the third and fourth tubes from axially moving relative to each other.
The carpet installation tool can further include a first lateral support block assembly that includes a first gripping block and a second gripping block configured to position laterally against the first tube support assembly and inhibit lateral movement of the first tube support assembly, the first and second gripping blocks each having carpet engaging protrusions on a bottom face configured to grip the carpet. A second lateral support block assembly includes a third gripping block and a fourth gripping block configured to position laterally against the second tube support assembly and inhibit lateral movement of the second tube support assembly, the third and fourth gripping blocks each having carpet engaging protrusions on a bottom face configured to grip the carpet.
In examples, the first angled wall engaging assembly includes a first support frame rigidly affixed to a first bumper, the first support frame comprising a plurality of attachment points along a length thereof, wherein the first tube support assembly is selectively coupled to one of the attachment points. In examples, the second support frame can include a C-frame. The central frame member can comprise a C-frame having a plurality of attachment points along a length thereof. The first tube support assembly is coupled to a first attachment point of the plurality of attachment points and wherein the second tube support assembly is coupled to a second attachment point of the plurality of attachment points. A foot of the hinge arm tool is positioned along the central frame at an intermediate position between the first and second tube support assemblies.
The present disclosure will become more fully understood from the detailed description and the accompanying drawings, wherein:
As will become appreciated from the following discussion, the present disclosure provides a carpet installation tool assembly that can be used to stretch carpet to minimize waves and bunching during installation of carpet in rooms that are not square. As noted above, in prior art examples, it is challenging to properly account for distribution of stretching forces between walls that are not parallel. In this regard, the carpet installation tool assembly according to the present disclosure distributes load toward the generally opposing, non-parallel walls more evenly while stretching the carpet to successfully remove waves to achieve a tight carpet profile across the entire carpet surface in the room.
With initial reference now to
With continued reference to
The first leg positioning assembly 30 includes a first tube support assembly 108 having a first tube 110, a second tube 112, and a first locking collar 116. The first leg positioning assembly 30 further includes a first lateral support block assembly 120 and a first angled wall engaging assembly 124. The first lateral support block assembly 120 includes a first gripping block 130 and a second gripping block 132. The first block 130 includes a rigid block member 140 having carpet engaging protrusions 142 on a bottom face that are configured to grip the carpet 60. The second block 132 includes a rigid block member 150 having carpet engaging protrusions 152 on a bottom face that are configured to grip the carpet 60. The gripping blocks 130 and 132 are placed laterally opposite the first tube support assembly 108 (at any location along its distance) and grip the carpet 60 while inhibiting lateral movement of the first tube support assembly 108 during use.
The first angled wall engaging assembly 124 generally includes a first support frame 160 rigidly affixed to a bumper 162. In examples, the bumper 162 can generally include a rigid support structure 170 and padded wall engaging portion 172. The first support frame 160 generally includes a rigid frame member having a plurality of attachment points, collectively identified at reference 180, along its length. In the example provided, the first support frame 160 is constructed as a c-frame having attachment points 180 defined through parallel walls 182, 184 that generally extend from a central wall 186.
The second leg positioning assembly 40 includes a second tube support assembly 208 having a third tube 210, a fourth tube 212, and a second locking collar 216. The second leg positioning assembly 40 further includes a first lateral support block assembly 220 and a second angled wall engaging assembly 224. The first lateral support block assembly 220 includes a third gripping block 230 and a fourth gripping block 232. The third block 230 includes a rigid block member 240 having carpet engaging protrusions 242 on a bottom face that are configured to grip the carpet 60. The fourth block 232 includes a rigid block member 250 having carpet engaging protrusions 252 on a bottom face that are configured to grip the carpet 60. The gripping blocks 230 and 232 are placed laterally opposite the second tube support assembly 208 (at any location along its distance) and grip the carpet 60 while inhibiting lateral movement of the second tube support assembly 208 during use.
The second angled wall engaging assembly 224 generally includes a second support frame 260 rigidly affixed to a bumper 262. In examples, the bumper 262 can generally include a rigid support structure 270 and padded wall engaging portion 272. The second support frame 260 generally includes a rigid frame member having a plurality of attachment points, collectively identified at reference 280, along its length. In the example provided, the first support frame 260 is constructed as a c-frame having the attachment points 280 defined through parallel walls 282, 284 that generally extend from a central wall 286.
A first pin 310 can selectively couple the first tube 110 to the central frame member 20. In particular, the first pin 310 can locate through a desired attachment point 100 along the central frame member 20 and through a bore 312 defined in the first tube 110. A second pin 320 can selectively couple the second tube 112 to the first support frame 160. In particular, the second pin 320 can locate through a desired attachment point 180 along the first support frame 160 and through a bore 322 defined in the second tube 112.
A third pin 330 can selectively couple the third tube 210 to the central frame member 20. In particular, the third pin 330 can locate through a desired attachment point 100 along the central frame member 20 and through a bore 332 defined in the third tube 210. A fourth pin 340 can selectively couple the fourth tube 212 to the second support frame 260. In particular, the fourth pin 340 can locate through a desired attachment point 280 along the first support frame 260 and through a bore 342 defined in the fourth tube 212.
A first torque applying assembly 344 includes a fifth pin 350, a sixth pin 352 and a line 356 connected therebetween. The line 356 can be any suitable connection such as, but not limited to, a cable, string, cord, rope or other feature. In use, the fifth pin 350 can be coupled to a suitable attachment point 100 on the central frame member 20 while the sixth pin 352 can be coupled to a suitable attachment point 180 on the frame 160. Proper tension can be applied between the pins 350 and 352 whereby a rotational force can be exerted on the first angled wall engaging assembly 124 that generally encourages the first support frame 160 to rotate around the second pin 320 transferring a rotational force 354 onto the angled wall 70 further maintaining the first support tube assembly 108 in a stable position and assisting in leveraging force toward the angled wall 70 while the hinge arm tool 50 urges the carpet 60 toward the straight wall 80 further stretching and removing any waves in the carpet 60.
A second torque applying assembly 358 includes a seventh pin 360, an eighth pin 362 and a line 366 connected therebetween. The line 366 can be any suitable connection such as, but not limited to, a cable, string, cord, rope or other feature. In use, the seventh pin 360 can be coupled to a suitable attachment point 100 on the central frame member 20 while the sixth pin 362 can be coupled to a suitable attachment point 280 on the frame 260. Proper tension can be applied between the pins 360 and 362 whereby a rotational force can be exerted on the second angled wall engaging assembly 224 that generally encourages the second support frame 260 to rotate around the fourth pin 340 transferring a rotational force 364 onto the angled wall 70 further maintaining the second support tube assembly 208 in a stable position and assisting in leveraging force toward the angled wall 70 while the hinge arm tool 50 urges the carpet 60 toward the straight wall 80 further stretching and removing any waves in the carpet 60.
The hinge arm tool 50 can include a telescoping leg assembly 380, a pivot arm assembly 382 and a carpet engaging pad 384. The pivot arm assembly 382 can have a pivot arm 386 and an urging arm 388. The carpet engaging pad 384 can include a rigid block member 390 having carpet engaging protrusions 392 on a bottom face that are configured to grip the carpet 60. The telescoping leg assembly 380 generally includes a first leg 396 and a second leg 398. Pivoting of the pivot arm 386 causes the first and second legs 396 and 398 to move axially away from each other causing opposing forces 400 and 402 between the carpet 60 and the central frame member 20. In particular, a toggle foot 410 pivotally coupled to the second leg 398 by a ninth pin 420 urges against the central wall 106 of the central frame member causing the central frame member 20 to transfer the force through the first and second support tube assemblies 108 and 208 and ultimately against the angled wall 70. Wheels 430 can be rotatably coupled to the toggle foot 410 for assisting in traversing the hinge arm tool 50 along the central frame member 20 between carpet stretching events.
During the pivoting of the pivot arm 386, creating the forces 400 and 402, the forces communicated along the first and second support tube assemblies 108 and 208 and ultimately against the angled wall 70 will create forces FA1, FA2, FA3, and FA4 onto the carpet 60 generally toward the angled wall 70 and forces FB1 and FB2 onto the carpet 60 generally toward the straight wall 80 removing any waves along a vast area of carpet. In particular, as the first and second support tube assemblies 108 and 208 span a distance along the angled wall 70 generally outboard of the hinge arm tool 50 and distribute significant gripping action across the carpet 60 along the angled wall 70, the carpet installation tool 10 provides improved and efficient stretching of carpet between angled walls. Additionally, the central frame 20 creates a virtual wall for leveraging forces between the central frame 20 and the angled wall 70 and between the central frame 20 and the straight wall 80 resulting in more efficient and even stretching along a wide span of carpet between non-parallel walls.
As shown in
It will be appreciated that the attachment points 100, 180 and 280 are shown and described as bores however other structures and/or mechanisms for selectively securing respective tubes 110, 112, 210 and 212 to the central frame member 20 and frames 160 and 260 may be used.
Turning now to
The carpet installation tool assembly 10 can have many additional uses such as extended length rooms including banquet halls. In other examples, the carpet installation tool assembly 10 can be particularly advantageous using in rooms with baseboard heat including hotels, churches and offices. Additionally, pattern match stretch applications or other situations where a stretch bearing wall is needed including funeral homes, corridors and other unique floorplans. The carpet installation tool assembly 10 can be anchored in wood floors and used with gripper boards, anchors and weights where needed to stretch and manipulate very large (such as 7 foot or more) pattern matched installations.
The foregoing description of the examples has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular example are generally not limited to that particular example, but, where applicable, are interchangeable and can be used in a selected example, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.
