Note: Descriptions are shown in the official language in which they were submitted.
CA 02955439 2017-01-20
HAND TOOL FOR BENDING REBAR
TECHNICAL FIELD
[0001] The present invention relates to tools used to bend rebar and other
long and slender objects.
BACKGROUND OF THE INVENTION
[0002] Rebar (short for reinforcing bar) is a steel bar used to reinforce
concrete and masonry structures. Rebar's surface is often patterned to form a
better
bond with the concrete. Straight lengths of rebar must often be bent into
desired
shapes at a shop or project site.
[0003] A hand tool known as a "Hickey bar" or "Hickey" is commonly used
by construction tradesmen to manually bend rebar. Hickeys have a tool head for
engaging the rebar and a long handle for applying force necessary to make the
bend. The tool head and handle are typically rigidly connected. The handle is
long
to provide a long lever arm so that greater bending moments (or torque) can be
achieved with manual strength.
[0004] "Bending moment" and "torque" may be used interchangeably herein
to indicate static or dynamic rotational forces at the tool head created by
manually
applied forces on the Hickey handle. The term "axis" with respect to bending
moment or torque refers generally to the torque axis, whether it is static or
dynamic. The axis of rotation of a Hickey bar or tool head is considered
herein to
be coincident with the torque axis for purposes of describing the invention.
The
bend of the rebar will generally be in a plane that is perpendicular to the
torque
axis. The term "bend axis" may be used to characterize the axis of a bend
radius,
which bend axis is considered herein to be parallel to the torque axis.
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[0005] A typical pin type of Hickey is shown FIGS. 5a and 5b, the tool
head
of which typically has three pins. The straight rebar is placed in the space
between
the pins, with one pin on one side of the rebar and two pins on the other
side. A
three-pin Hickey provides three placement options, so that the Hickey handle
may
be oriented in one of three orientations relative to the rebar.
[0006] Another popular type of Hickey is shown in FIGS. 6a and 6b, which
has a U-shaped tool head for engaging the rebar and which provides only one
possible orientation of the handle to the rebar.
[0007] There is a need for a Hickey that provides a greater range of
possible
handle orientations so that tradesmen can position the Hickey handle in more
advantageous orientations, so as to provide improved ergonomics, better
leverage,
less injury, and improved access to and maneuverability in tight spaces. There
is a
need for a Hickey that allows adjustment of the handle orientation without
disengagement of the tool head from the rebar, so that a bend can be made in
increments and the handle can be optimally positioned for each increment
according to the preferences of the tradesman or according to other parameters
such as workspace restrictions.
[0008] The present invention fills those and other needs.
SUMMARY OF THE INVENTION
[0009] In a first aspect, the present invention provides a hand tool for
bending rebar, comprising: a ratchet mechanism; a handle extending from the
ratchet mechanism; and a hickey tool head connected to the ratchet mechanism.
The tool head comprises at least one engagement surface for engaging rebar.
The
at least one surface forms a space for receiving the rebar.
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[0010] In a second aspect, the present invention provides a tool head for
a
rebar bending tool, comprising: a base adapted for attachment to a drive; and
at
least one engagement surface for engaging rebar and transmitting torque to the
rebar. The at least one surface forms a transverse space for receiving the
rebar in a
transverse orientation to the torque axis.
[0011] In a third aspect, the present invention provides a tool for
bending
rebar, comprising: a base adapted for attachment to a driving device; a
plurality of
spaced apart extensions extending from the base so as to form a plurality of
transverse spaces for receiving rebar; a ratchet mechanism releasably
attachable to
the base; and a handle attached to the ratchet device. The plurality of spaces
comprise a first space having a first width to fit over rebar of a first
standard rebar
diameter and second space having a second width to fit over rebar of a second
standard rebar diameter.
[0012] In a fourth aspect, the present invention provides a method of
manufacturing a hickey bar tool head, comprising the steps of: machining into
a
block at least one transverse channel for receiving a rebar; and machining
into the
same block surfaces for engagement with a drive mechanism.
[0013] In a fifth aspect, the present invention provides method of bending
rebar, comprising the steps of engaging a ratcheting hickey bar with the
rebar;
applying torque to the hickey bar in the locked direction of the ratchet
wherein the
rebar bends as the hickey bar handle and the head rotate from a first position
to a
second position in response to the torque
[0014] In a sixth aspect, the present invention provides a tool kit
comprising
at least one Hickey bar tool head and at least one ratchet mechanism
compatible
for connection with at least one of the at least one tool head.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The subject matter that is regarded as the invention is
particularly
pointed out and distinctly claimed in the concluding portion of the
specification.
The invention, however, may be best understood by reference to the following
detailed description of various embodiments and the accompanying drawings in
which:
[0016] FIG. 1 is a perspective view of one embodiment of a Hickey bar in
accordance with the present invention, with only part of the handle length
showing;
[0017] FIG. 2a is a side view of the Hickey bar of FIG. 1 with the handle
length shown in broken view;
[0018] FIG. 2b is a top view of the Hickey bar of FIG. 2a;
[0019] FIG. 2c is a bottom view of the Hickey bar of FIG. 2a;
[0020] FIG. 2d is an end view of the Hickey bar of FIG. 2a;
[0021] FIG. 2e is a perspective view of an embodiment of a ratchet
mechanism that may be utilized in an embodiment of the present invention.
[0022] FIG. 3a is a perspective view of the tool head of the Hickey bar of
FIG. 1;
[0023] FIG. 3b is a side view of the tool head of FIG. 3a;
[0024] FIG. 3c is a top view of the tool head of FIG. 3b;
[0025] FIG. 4a is a perspective view of a Hickey bar of the present
invention
in operation bending a piece of rebar;
[0026] FIG. 4b is an enlarged view of the portion of FIG. 4a identified by
line A-A in FIG. 4a;
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[0027] FIG. 5a is a perspective view of a type of Hickey bar of the prior
art;
[0028] FIG. 5b is an enlarged view of the portion of FIG. 5a identified by
line A-A in FIG. 5a;
[0029] FIG. 6a is a perspective view of another type of Hickey bar of the
prior art;
[0030] FIG. 6b is an enlarged view of the portion of FIG. 6a identified by
line A-A in FIG. 6a.
DETAILED DESCRIPTION OF THE INVENTION
[0031] With reference to FIGS. 1 and 2a-2d, a preferred embodiment of the
present invention comprises handle 10 attached to ratchet mechanism 20
attached
to tool head 30. The ratchet mechanism, like those typical of many
commercially
available ratcheting socket wrenches, has operational modes in which the drive
is
locked relative to the handle in one rotational direction and free to turn
relative to
the handle in the opposite direction. The operational modes can be easily
switched
from one direction to the other. In the embodiment of FIG. 2a-2d, a switch
lever
21 is provided to change the ratchet mode between locked-clockwise and locked-
counterclockwise. Other ratchet modes may include locked in both directions
and
free in both directions. The Hickey bar and rebar need not be disengaged to
switch
modes.
[0032] Certain embodiments of the present invention may comprise
commercially available ratchet mechanisms and tool heads constructed to be
compatible with commercially available ratchet mechanisms. Other embodiments
may comprise ratchet mechanisms specifically designed for Hickey bar
application
and for the high loads necessary to bend rebar.
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[0033] An example of a commercially available female ratchet drive is
Protog Industrial Tools item number J5649FW 3/4" Ratchet Female Drive with
20" handle, and an example of a commercially available male ratchet drive is
Snap-on item L873 1" Square Drive Sealed Ratchet Head. There are many
others.
[0034] With reference to FIG. 2e, the drive portion of a typical
commercially
available ratchet mechanism is shown, having a square drive peg 25. Drive peg
25
has lateral sides 29, beveled top edges and corners forming round top surface
28, a
round shoulder 27 at the base of the peg, and a releasable lock pin 26 or
equivalent
lock ball for engaging a corresponding hole or indentation in the tool head.
The
peg's longitudinal axis corresponds with its axis of rotation when it rotates
relative
to the Hickey bar handle. The "drive axis" or "axis of rotation" may refer to
the
axis of rotation of a male drive ratchet or female drive ratchet relative to
the
handle. The tool head of the present invention may be configured to be
releasably
attachable to the drive in like manner as sockets are in commercially
available
ratcheting socket wrench sets, and may comprise a hole or indentation in the
tool
head for receiving releasable lock pin 26 or equivalent lock ball.
[0035] In another embodiment of the present invention, the tool head is
securely fastened to the drive peg using any suitable manner for secure
attachment,
such as a pinned joint. With reference to FIGS. 2a and 3a, tool head 30 may be
provided with a pin hole 36. The drive peg may be provided with a
corresponding
pin hole (not shown) aligned with pin hole 36. A pin (not shown) may be
installed
in the pin holes, said pin having an inteiference fit with the holes, to form
a secure
joint. This embodiment may comprise a drive without a releasable lock means
such as a releasable pin 26 or equivalent releasable ball. Such a non-
releasable
joint may be preferred to ensure robust connection and prevent inadvertent
release
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of the tool head from the ratchet mechanism under the rigorous loading
conditions
often encountered in service.
[0036] In other embodiments, the present invention may comprise fixed
drives with no ratchet mechanism. In yet other embodiments, the tool head may
be
integral to the drive and may be integral to the handle.
[0037] With reference to FIGS. 3a-3c, a preferred embodiment of the tool
head may comprise a base 31 having upward facing surface 32 and a plurality of
upwardly extending members 34 having lateral sides 35. The spaces between
sides
35 of members 34 form transverse channels 41, 42 and 43, each channel
extending
across the tool head. Each member 34 may have different dimensions than other
members 34 as necessary to form channels of desired width. In FIG. 3c, channel
41 is wider than channel 42, and channel 42 is wider than channel 43. Member
34
between channels 41 and 42 has a smaller cross section than the member between
channels 42 and 43.
[0038] The tool head may comprise a spacer 33 extending below base 31,
said spacer for contacting the ratchet drive and maintaining clearance between
the
base and ratchet mechanism.
[0039] The tool head of the present invention may be manufactured from a
block by machining away the material necessary to form channels of desired
dimension. Thus, members 34 are formed from remaining material of the block
between the channels, as shown in FIG. 3a. Thus the present invention provides
for improved manufacturing methods. Most efficient use of materials is
achieved,
which allows for smaller tool heads and provides stronger upward extending
members 34. Side surfaces 35 of members 34 contact the rebar during bending
operations and transmit the bending torque to the rebar. Members 34 and
surfaces
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35 have material properties sufficient to withstand these forces without undue
deformation.
[0040] In some embodiments, the channels may comprise a round hole bored
transversely through the tool head. The hole may be manufactured in any
desirable
cross sectional shape. In those embodiments, the channels are not open to the
top
of the tool head.
[0041] The tool head of the present invention may comprise a single piece
of
material, thus providing a more robust tool head and eliminating assembly
steps
such as assembling pins to the tool head as may be necessary for the Hickey
bar of
FIG. 5a.
[0042] The tool head may comprise metal or any other suitable material.
The
tool head may comprise steel and may comprise tool steel.
[0043] In the embodiment shown in FIGS. 3a-3c, the channel sides are
opened to the top of the tool head so that the tool head may receive sideways
insertion of rebar through the top of the tool head. The tool head may be
positioned adjacent to a length of rebar at mid span, with the top of the head
facing
the side of the rebar and with a channel aligned with the rebar. The rebar
and/or
Hickey may then be moved sideways with respect to the rebar to insert the
rebar
into the channel, thus engaging the head and rebar for subsequent bending
operations. FIGS. 4a and 4b show a Hickey bar of the present invention engaged
with a rebar, shown after the bending operation has taken place.
[0044] The "sideways" directional reference for describing relative
movement or special relationship of the tool and rebar indicates sideways with
respect to the rebar.
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[0045] In an alternate embodiment, the top side of the channel may be
closed
or have an undersized opening. In that. case, the rebar may be received
endwise
through the side of the tool head into an open end of a channel. In this
alternate
embodiment, the bar is securely captured from unintended disengagement out
from
the top of the tool head during bending operations.
[0046] The tool head may comprise a plurality of channels. A channel may
intersect one or more other channels. The embodiment of FIG. 3c comprises
three
channels, each having a different width than the other two, and all
intersecting in
the middle of the tool head. Channel widths may be sized to fit standard size
rebar.
For example, channels 41, 42 and 43 may be sized to fit three different
standard
sizes, such as standard bar sizes #5, #4, and #3, respectively. Channel widths
may
be sized to provide a clearance fit with the intended bar size diameter.
[0047] With further reference to FIGS. 1-3b, the tool head is provided
with a
square opening 44 for receiving square drive peg 25. Pin hole 36 is provided
for
alignment with a corresponding pin hole (not shown) in the drive peg and
receiving
a pin to securely affix the tool head to the drive peg. In a preferred
embodiment,
opening 44 is sized for compatibility with a one inch (1") square drive.
Opening
44 may be sized for compatibility with other drive sizes. For example, it may
be
sized for compatibility with other standard drive sizes.
[0048] In other embodiments, opening 44 may be of any shape to correspond
with the shape of the desired drive, such as any polygonal shape or splined
shape.
[0049] In another embodiment, the tool head may be configured to be
compatible with a female drive, such as a ratchet wrench with a female drive.
In
this embodiment, the base of the tool head may comprise a downward extension
of
polygonal cross section corresponding to the shape of the opening of the
female
drive. Said downward extension may be square, hexagonal, or any other shape to
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correspond with the shape of the desired drive, such as any standard size
drive.
The cross section may be of a splined shape.
[0050] The term "coupling" herein may refer to a male or female feature of
the tool head for connecting with a corresponding female or male drive,
respectively.
[0051] With reference to FIGS. 3a-3c, the external sides of base portion 31
may be engaged directly by a driving device. The hexagonal shape of the tool
head of FIGS. 3a-3c is particularly suitable for such engagement. For example,
an
open ended wrench of appropriate size could engage the hexagonal shape.
[0052] In other embodiments, the bottom portion of the base may be provided
in any shape to facilitate engagement with a driving device of desired shape.
[0053] A driving device may be any device suitable for attaching to and
applying torque to the tool head.
[0054] In the embodiment of FIGS. 1-3c, channels 41, 42 and 43 intersect
the drive axis of rotation. Thus, when the Hickey bar is in operational
engagement
with a length of rebar, the axis of rotation of the drive intersects the
rebar. The
drive axis of rotation is perpendicular to the longitudinal axis of rebar.
This tool
head configuration and geometric relationship between the Hickey bar and rebar
provides efficiencies and advantages, such as mechanical advantages,
operational
advantages, tool design efficiencies, manufacturing efficiencies, space
utilization
advantages, and other advantages.
[0055] Two Hickey bars of the present invention may be used together to
bend rebar by engaging the rebar at two locations and applying torque to each
tool
head in opposite directions.
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[0056] A hickey bar of the present invention may comprise a handle
attached
to a ratchet attached to a tool head type shown in FIGS. 5a-6b, or any other
tool
head design adapted for engagement with and bending of rebar.
[0057] A kit of the present invention may comprise one or more a separate
handles, ratchet mechanisms, tool heads and drive size adapters. Another kit
may
comprise one or more preassembled handle and tool head assemblies.
[0058] The device of the present invention may be used to engage and bend
any long, slender, bendable object, such as threaded rods, grounding rods, and
pipe.
[0059] While the invention has been particularly shown and described with
reference to certain embodiments, it will be understood by those skilled in
the art
that various changes in form and details may be made to the invention without
departing from the spirit and scope of the invention as described in the
following
claims.
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