Note: Descriptions are shown in the official language in which they were submitted.
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Pneumatic Carpet Setter
Field of the Invention
The invention relates generally to carpet setters, and more particularly
to carpet setters wherein the force for stretching the carpet is provided. by
mechanical means.
Backgroun.d of the Invention
Carpet setters for the installation of carpet are known in the art. Such
carpet setters allow the carpet to be placed under tension prior to being
nailed
down to a tack board that is located at the perimeter of the floor being
carpeted.
A first group of carpet setters encompasses those that use a "kicking"
action for the application of force to the carpet. The simplest of these
comprise a knee pad, on to which the operator applies a kicking force with his
or her knee, a gripping head that engages the carpet being stretched and a
ram between the knee pad and the gripping head. A carpet setter of this type
is outlined in United States Patent 2,631,403 to Hopkins et al. Hopkins et al,
disclose a solid ram between the knee pad and the gripping head.
Carpet setters of the above type are widely used due to their ease of
use. However, there are known disadvantages associated with the use of
these carpet setters. First, the "kicking" action with the operator's knee may
lead to injuries due to the impact stress placed on the knee. Second, the
force applied to the carpet can be sufficient to result in tearing of the
carpet.
United States Patent 4,627,653 to Koroyasu discloses a carpet setter
of the kicking type that implements an air cylinder between the knee pad and
the gripping head. This system is designed to provide shock absorbing
capabilities thereby reducing the stress on the operator's knee. The system is
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also designed to reduce the tearing that may occur due to the magnitude of
the applied force and of the acceleration of the gripping head during the use
of the carpet setter. The carpet setter of Koroyasu continues to use a
"kicking" action to provide the mechanical force required to stretch the
carpet.
A second group of carpet setters implement some form of mechanical
force for the stretching of the carpet that is not provided through a
"kicking"
action of the operator. Generally this type of carpet setter uses a "pulling"
force to stretch the carpet. Carpet setters of this type generally comprise
three basic elements: a means for engaging the tack board to which the
carpet will be affixed, a gripping head to engage the carpet and a mechanical
means for reducing the distance between the first two elements. Numerous
mechanical means and setter arrangements have been used to provide the
pulling force and then transfer this force to the carpet.
For example, United States Patents 3,980,274 and 3,963,216 to Ebert
and Victor, respectively, implement a lever mechanism. An implementation
that uses an air cylinder is disclosed in United States Patent 4,042,211 to
Hammond et al. Finally, United States Patents 5,145,225 and 6,371,446 to
Mullel et al. and Gauthie et al., respectively, disclose the use of pneumatic
cylinders as a means of generating the force for stretching the carpet. These
latter two carpet setters again use a pulling arrangement to stretch the
carpet.
Generally, the carpet setters of this type are more awkward to use than the
kicking type of carpet setters. In particular the required engaging of the
tack
board adds complexity to their operation as carpet setters.
United States patent 4,084,787 to Kowalczyk discloses a mechanical
type carpet setter that can stretch the carpet in either pulling or pushing
mode
of operation. In the former mode the carpet setter uses an anchor that
engages the tack board to which the carpet is being attached while in the
latter mode a pole that is abutted against the wall opposite to that where the
carpet is being stretched is implemented. Kowalczyk discloses that the
mechanical force can either be generated by a hydraulic system or a motor
and gear system. Further it is disclosed that the switch controlling the above
systems allows for the selection of "forward" and "reverse" directions. From
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the above it is apparent_ that in the system of Kowalczyk the movement of the
ram/ gripping head is slow with gradual acceleration and the gripping head
does not automatically return to its initial position.
Therefore, there is a need for a carpet setting device that is used in a
manner similar to kicker type carpet setters and does not require the operator
to strike the carpet setter for the generation of the force required to
stretch the
carpet. Further, there is a need for a carpet setter that develops a force
that
is similar to that generated by a kicker type carpet setter.
io Summary of the Invention
The invention is directed to a carpet setter that is used in a manner
similar to kicker type carpet setters and uses means other than the operator
to
generate an impact type force for stretching the carpet.
In accordance with an aspect of the invention a carpet setter is
ls provided. The carpet setter comprises a gripping head having a plurality of
prongs extending downwardly therefrom wherein the plurality of prongs are
adapted for engaging a carpet, at least one handle and a mechanical system
for providing an impact type force to the gripping head, the force being
generated within the system by mechanical means.
20 In accordance with another aspect of the invention a method of setting
a carpet with a carpet setter is provided. The method comprises the steps of
aligning the carpet setter such that a plurality of prongs of a gripping head
comprised by the carpet setter are aligned appropriately for engaging the
carpet, engaging the carpet with the plurality of teeth, providing a supply of
25 fluid to a fluid cylinder of the carpet setter to thereby slidably move a
piston
contained within the cylinder, and communicating the sliding movement of the
piston to the plurality of teeth such that the carpet is stretched.
Other aspects and advantages of the invention, as well as the structure
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and operation of various embodiments of the inverition, will become apparent
to those ordinarily skilled in the art upon review of the following
description of
the invention in conjunction with the accompanying drawings.
Brief Description of the Drawings
The invention will be described with reference to the accompanying
drawings, wherein:
Figure 1 is a side view, of a pneumatic carpet setter according to one
embodiment of the invention;
Figure 2a is a top view, of a pneumatic carpet setter according to
another embodiment of the invention, with the pneumatic cylinder in the
retracted position;
Figure 2b is a top view, of a pneumatic carpet setter according to
another embodiment of the invention, with the pneumatic cylinder in the
extended position;
Figure 3a is a side view, presenting detail of a cover for a carpet setter
according to one embodiment of the invention;
Figure 3b is a side view, presenting detail of a cover for a carpet setter
according to one embodiment of the invention wherein the carpet setter has
been "fired"; and
Figure 4 is a schematic diagram of the air circulation system according
to one embodiment of the invention.
Like numerals are used to represent like elements in the Figures.
Detailed Description of the Invention
The invention provides a carpet setter whose form factor is similar to
that of kicker type carpet setters. The invention further provides a carpet
setter where the force for stretching the carpet is an impact type. In the
current exemplary embodiment the force is provided by a pneumatic cylinder.
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Figure 1 is a side view of a pneumatic carpet setter according to the
current exemplary embodiment of the invention. A carpet setter 10 includes a
body or housing 12 and a cover 14. The housing 12 includes a forward end
15 and a rearward end 17. Attached to the cover 14 are a forward handle 16
and a rear handle 20. The forward handle 16 and the rearward handle 20 are
affixed to the cover 14 at a raised portion 21. The handles 16 and 20 allow an
operator to hold the carpet setter 10. By holding the handles 16 and 20 of the
carpet setter 10 the operator becomes the primary means of maintaining the
position of the carpet setter during its operation. Attached to and integral
with
the forward handle 16 is a trigger lever 18. The trigger lever 18 is adapted
for
operation by the hand of the operator that is holding the forward handle 16.
Protruding from the front end of housing 15 is sliding shaft 36 and a fixed
sheath 38. The sliding shaft 36 is slidable within the fixed sheath 38, which
is
affixed to the housing 12. A gripper head 22 is affixed to the sliding shaft
36.
is Extending downward from the bottom of the gripper head 22 is a plurality of
gripping prongs or teeth 24. The gripping teeth 24 are appropriate for
engaging a carpet. An adjuster 26 adjusts the distance the gripping teeth 24
extend from the gripper head 22. A second set of gripping prongs 27 is
provided at the rear of the carpet setter 10. The prongs 27 are designed to
also engage the carpet. The prongs 27 assist in arresting the carpet setter 10
from sliding backwards during operation. An air inlet port 28 is present at
the
rear of the housing 12. An air exhaust port 29 is also provided at the rear of
the carpet setter 10.
A top view of the carpet setter 10 with the cover 14 is removed from the
carpet setter 10 is shown in Figure 2a and 2b. Thus Figure 2a details
features of the carpet setter 10 according to the current exemplary
embodiment including features that are internal to the housing 12. Central to
the carpet setter 10 is a pneumatic cylinder 30. The pneumatic cylinder 30 is
affixed (not shown) to the housing 12. A piston 31 is located within the
pneumatic cylinder 30. The piston 31 is appropriate for receiving pressurized
air within the pneumatic cylinder 30 and providing a sliding mechanical force
to a ram 32, which is attached to the piston 31. The pressurized air used in
the current embodiment may be provided by any appropriate means external
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to carpet setter 10. In the current embodiment an air compressor provides the
pressurized air to be to pneumatic cylinder 30. The ram 32 extends from one
end of the cylinder 30. The ram 32 is shown in a retracted position in Figure
2a. The arrangement of the piston 31 in Figure 2a is for illustrative purposes
only. One of skill in the art will appreciate the arrangement of the piston 31
within the cylinder 30. The invention encompasses all means of converting
the force associated with pressurized air within the cylinder 30 to a slidable
mechanical force that is provided to the ram 32.
When in the extended position the ram 32 contacts a proximal end of
the sliding shaft 36. Affixed to the proximal end of the sliding shaft 36 is a
forward travel stop 34. The forward travel stop 34 determines the distance
travelled by the sliding shaft 36 and in turn the gripper head 22 as shown in
Figure 2b. This distance is set such that any wrinkles in the carpet being set
are removed while not being large enough to possibly damage the carpet.
Connected between the sliding shaft 36 and the housing 12 are springs 40.
The springs 40 return the sliding shaft 36 and the gripper head 22 to a
retracted position after the ram 32 has returned to a retracted position. The
invention is not to be limited by the use of springs. Other means of returning
the sliding shaft 36 to a retracted position will be apparent to one of skill
in the
art and are encompassed by the invention.
Detail of the cover unit components is presented in Figure 3a and 3b.
A firing arm 42, a pivot point 43, a pneumatic switch 44 and a return spring
46
are within or directly under a region defined by the raised portion 21 of the
cover 14. The firing arm 42 rotates about the pivot point 43. During rotation
about the pivot point 43, the firing arm 42 engages a contact point 48 of the
pneumatic switch 44. Figure 3a illustrates the state where the trigger is
unfired and Figure 3b illustrates the state where the trigger is fired. When
"fired" the firing arm 42 engages and displaces the contact point 48 of the
pneumatic switch 44. The return spring 46 is initially in a retracted state,
as
seen in Figure 3a. Once "fired" the return spring 46 is extended and will
return the firing arm 42 to its original state once the trigger 18 is
reieased.
Figure 4 is a schematic diagram of air supply system 51, which is the
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system of the current exemplary embodiment that supplies pressurized air to
the pneumatic cylinder 30. A conduit 50 is attached to and receives the
pressurized air from air inlet port 28 that extends firom the rearward end 17.
The conduit 50 is in turn attached to and supplies air to the pneumatic switch
44. Conduits 52 and 58 are attached to and receive air from the pneumatic
switch 44. The conduit 52 is attached to a quick exhaust valve 54 while the
conduit 58 is attached to a rear port 59 of the air cylinder 30. A conduit 56
is
attached to and receives air from the quick exhaust valve 54. The conduit 56
provides air to a front port 57 of the cylinder 30. Thus air is provided to
the
cylinder 30 via a front port 57 and a rear port 59. The cylinder 30 that is
appropriate for use with such an air supply system will be apparent to those
of
skill in the art.
The air supply system 51 and the pneumatic cylinder 30 are designed
to provide for rapid acceleration of the ram 32. They are further designed
such that the magnitude of the force provided by them, in conjunction with the
acceleration of the ram 32, provide for an impact type force. This force
provides for a movement of the ram 32 that is sirriilar to that provided by a
kicker type carpet stretcher. In the kicker type carpet stretcher this
movement
is provided by the impact of the operator's knee striking a knee pad. Further,
the air supply system of the current exemplary embodiment allows for the
return of the piston, and in turn the ram 32, to its original position
automatically.
The operation of the carpet setter of the instant invention according to
an embodiment of the invention will now be considered. In this embodiment
the carpet is a jute backed carpet. A narrow strip of wood with upward facing
tacks or "tack strip" is arranged around the perimeter of the floor on which
carpet is to be laid, adjacent to the walls at the edges of the floor. The
carpet
to be laid is trimmed to fit the floor to be carpeted, as will be apparent to
one
skilled in the art. One edge of the carpet is secured to a tack strip adjacent
to
a wall of the room in which carpet is to be laid. The carpet setter according
to
an embodiment of the invention is then set on the carpet at an edge opposite
to that anchored to the tack strip. The setting of the carpet setter is such
that
the front most edge of the gripping head 22 is spaced within about several
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inches from the wall. The gripper adjuster 26 is adjusted such that the teeth
24 penetrate the desired amount into the carpet, as will be apparent to one
skilled in the art. In this embodiment the carpet setter 10 is held such that
the
prongs 27 engage the carpet.
With the carpet setter aligned as above the operator who is using the
carpet setter of the current invention kneels to the side of the setter. One
hand of the operator engages the forward handle 16 while the other hand
engages the rear handle 20. The operator engages the trigger lever 18 to
"fire" the carpet setter. With the "firing" of the carpet setter a portion of
the
carpet in the vicinity of the carpet setter is stretched such that it is
taught. The
carpet is then secured to the tack board over which the carpet is being
stretched. Alignment of the carpet setter such that the prongs 27 engage the
carpet assists in preventing the carpet setter from moving backwards during
operation. Once the carpet is secured to the tack board the operator moves
an appropriate amount in a direction parallel to the wall to a portion of the
carpet that has not been stretched. The carpet setter is then used to stretch
this portion of carpet.
The operation of the various components of the carpet setter described
above will now be discussed. When the trigger lever 18 is engaged the
trigger lever 18 moves toward the forward handle 16 as shown in Figure 3b.
With this action the firing arm 42 rotates about the pivot point 43 and
thereby
engages the pneumatic switch 44. The return springs 46 are extended with
the above operation.
The operation of the air supply system will now be discussed with
reference to the schematic diagram of Figure 4. Elements of the system that
supplies air to the pneumatic cylinder 30, according to the current exemplary
embodiment, are shown in Figure 4. Pressurized air enters the supply system
via an air inlet 50. The air inlet 50 begins as inlet port 28. Apart from a
portion of the air inlet 50 that forms the air intake 28 the air supply system
is
contained within the housing 12. The pressurized air is suppiied from the air
inlet 50 to the pneumatic switch 44. When the pneumatic switch 44 is
triggered through the engagement of the trigger lever 18 the air is supplied
to
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a quick exhaust valve 54 via the conduit 52 and the rear port 59 via the
conduit 58. Air travels through the quick exhaust valve 54 and is supplied to
a
front port 57 via the conduit 56. Pressurized air is supplied to both sides of
the piston 31. The quick release valve 54 then provides for the rapid release
of pressurized air from the cylinder 30 through the front port 57 allowing the
piston to slidably move in the cylinder 30 such that the ram 32 extends from
the cylinder 30. The air exhausts from the quick exhaust valve 54 and exists
the carpet setter 10 at a port 29. Details of the operation of pneumatic
cylinder 30 and will be apparent to those of skill in the art.
As shown in Figure 2b the "firing" of the carpet setter causes the ram
32 to extend outward from the cylinder 30. During the above extension the
ram 32 slidably moves the sliding shaft 36 and the gripper head 22 forward.
In an alternative embodiment the fluid cylinder 1 is appropriate for
operation with a liquid such as oil or water.
In a further alternative embodiment the air supply system 51 is any
system that is appropriate for, in conjunction with the cylinder 30, providing
an
impact type force to ram 32.
In a further alternative embodiment the carpet setter 10 is held such
that the rearward end thereof is raised above the carpet.
In a further alternative embodiment the cylinder 30 and fluid supply
system is appropriate for the supply of fluid to the cylinder 30.
In a further alternative embodiment the carpet is any carpet for which
the stretching of the carpet is a step in the laying of it.
While the invention has been described according to what is presently
considered to be the most practical and preferred embodiments, it must be
understood that the invention is not limited to the disclosed embodiments.
Those ordinarily skilled in the art will understand that various modifications
and equivalent structures and functions may be made without departing from
the spirit and scope of the invention as defined in the claims. Therefore, the
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invention as defined in the claims must be accorded the broadest possible
interpretation so as to encompass all such modifications and equivalent
structures and functions.
