Sheet metal straightening device

A hole straightening apparatus for removing surface deformities in a desired surface shape. A frame is pivotally attached to a handle. The handle is pivotally attached to a moving jaw that is slidingly engaged with the frame. When the handle is motivated towards the frame, a moving jaw is caused to slide along a surface of the frame towards a stationary anvil. Sheet metal to be straightened is captured between an anvil surface of the moving jaw and an anvil surface of the stationary anvil, causing a compressive force between the two anvil surfaces. Sequential operation of the handle causes sequential compressive forces to be applied to the deformed sheet metal structure as the stationary anvil is rotated around the edge of the hole. As a result, the deformed edges of the hole in the sheet-metal structure are substantially straightened.

Not applicable.

Not applicable.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The field of the invention relates generally to systems and methods for repairing deformed structures such as automobile bodies and body parts. More specifically, in embodiments, the invention relates to systems and methods for producing a desired surface in a vehicle body or body part in or near a location on the structure in which a hole is located during the course of repair of a body part, after the body part has been subjected to unwanted disfiguring forces that have resulted in undesired protuberances, creases, bends, and other disfigurements and deformities that cause the body part to have a surface shape and appearance that is not in conformity with a desired surface shape. The desired surface shape may be flat or curved along one or more cross sections. The body part may, but does not necessarily, comprise sheet metal structures.

2. Background Art

There are many scenarios in which it is desired to return a disfigured sheet structure to a desired surface shape. Such disfigured sheet structures may result, for example, in the case in which vehicle body parts have been subjected to disfiguring forces resulting from collisions between vehicles, or between a vehicle and another stationary or moving object. In some cases the disfiguring forces causing the unwanted disfigurement may result from other body or repair work that is being performed upon a vehicle. In another non-limiting case, the disfiguring forces may result from severe weather, such as may be caused by the impact of hail or falling ice on a sheet structure, leaving unwanted dents in the sheet structure that cause the sheet structure to have a surface shape and appearance that is not in conformity with a desired surface shape, which may be flat or cured along one or more cross sections. Non-limiting examples of sheet structures that have been disfigured and thus have a surface shape that is not in conformity with a desired planar shape due to hail damage are automobile bodies, motorcycle body parts, and metal roofs such as, for example, corrugated metal roof panels and the like. Often such structures contain holes, around which the sheet structure has been deformed. Such deformities may occur during vehicle body work when panels are detached from a vehicle. In many cases, it is required that such deformities be substantially removed from surfaces that are not feasible to place in a floor machine press due to the shape of the part, or the construction of the part, or for other reasons.

What is needed in the art, therefore, is an apparatus and/or method adapted to quickly and efficiently straightening of deformities surrounding a hole in a sheet metal surface for which it not feasible to use a floor machine press, substantially and quickly returning the sheet metal surface to a desired surface shape.

BRIEF SUMMARY OF THE INVENTION

The present invention comprises an apparatus and method that have one or more of the following features and/or steps, which alone or in any combination may comprise patentable subject matter.

In accordance with one embodiment of the present invention, the invention comprises a hole straightening apparatus, comprising: a handle pivotally attached to a frame; a moving jaw comprising an anvil surface, wherein the moving jaw is slidingly engaged with a surface of the frame; a stationary jaw comprising an anvil surface wherein the stationary jaw is attached to the frame; and a lever pivotally attached to the frame and pivotally attached to the handle; wherein when the handle is motivated towards the frame, a surface of the lever is in contact with and motivates the moving jaw along a surface of the frame towards the stationary jaw; the hole straightening apparatus having a closed state wherein the anvil surface of the moving jaw is in contact with, and exerts a compressive force against, the anvil surface of the stationary jaw; and the hole straightening apparatus having an open state wherein the anvil surface of the moving jaw is motivated away from the anvil surface of the stationary jaw, creating an anvil gap between the he anvil surface of the moving jaw and the anvil surface of the stationary jaw; and wherein the stationary anvil has a width less than a dimension of a hole in a sheet metal structure desired to be straightened.

In embodiments, the moving anvil may have a width less than a dimension of a hole in a sheet metal structure desired to be straightened.

In embodiments the stationary jaw may be fabricated from sheet steel.

In embodiments, the stationary jaw may be interchangeable with other stationary jaws of differing dimension to accommodate a variety of dimensioned or shaped holes in a sheet structure to be straightened. In embodiments, the stationary jaw may be releasably attached to the frame.

In embodiments the moving jaw may be fabricated from sheet steel.

In embodiments the invention may comprise a threaded compression force adjusting rod threadingly engaged with the frame and protruding into the frame, wherein a distal surface of the threaded compression force adjusting rod is in contact with a surface of a lever pivotally attached to the handle such that when the threaded compression force adjusting rod is rotated so as to protrude further into the frame, the compressive force is increased when the hole straightening apparatus is in a closed state, and when the distal surface of the threaded compression force adjusting rod is rotated so as to proceed further out of the frame, the compressive force is decreased when the hole straightening apparatus is in a closed state.

The present method and device of the invention overcome the shortcomings of the prior art by providing a handheld tool for quick and efficient straightening of deformities surrounding a hole in a sheet metal surface, substantially and quickly returning the sheet metal surface to a desired surface shape.

In the figures, like callout numbers refer to like features.

DETAILED DESCRIPTION OF THE INVENTION

The following documentation provides a detailed description of the invention.

Although a detailed description as provided in the attachments contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following preferred embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, and not merely by the preferred examples or embodiments given.

As used herein, “disfiguring forces” includes within its meaning one or more forces that, when acting upon a sheet structure, cause the structure to be deformed such that a surface of the sheet structure no longer conforms to a desired surface shape.

As used herein, “desired surface shape” includes within its meaning any desired surface shape. A non-limiting example of a desired surface shape is a plane, which plane may be flat or may be a curved plane. As another non-limiting example, the desired surface shape may be that of a curved plane that is characterized by one or more curvilinear cross sections of the sheet structure. The desired surface shape may be any surface shape desired by a user.

As used herein, “hole to be straightened” and “sheet metal structure to be straightened” refer to a sheet metal surface having undesired deformities that depart from a desired surface shape, for which the removal of the deformities such that the sheet metal structure is substantially returned to a desired surface shape (“straightening”) is desired. Such undesired deformities may be the result of the prior application of disfiguring forces to a sheet structure.

As used herein, “closed state” means that state in which moving jaw106and moving anvil105have been motivated in the direction of arrow B, as depicted in the figures, towards stationary anvil113such that an anvil surface of moving anvil105is in contact with and is pressed against an anvil surface of stationary anvil113with a closing force F. The compressive force F pressing moving anvil105into stationary anvil113is also the force that is applied to the upper and lower surfaces of a deformed sheet metal structure for which it is desired to straighten the edges of a hole disposed in the sheet metal structure.

As used herein, “open state” means that state in which moving jaw106and moving anvil105have been motivated in the direction of arrow B, as depicted in the figures, away from a stationary anvil113such that an anvil surface of moving anvil105is no longer in contact with, and is motivated away from, the anvil surface of stationary anvil113. In the open state, there is no force asserted between the anvil surfaces of stationary anvil113and moving anvil105. When the hole straightener of the invention is disposed in an open state, it is possible to motivate stationary anvil104through a hole to be straightened and to translate stationary anvil104along the sheet-metal surfaces surrounding the hole to be straightened, sequentially straightening the sheet metal surrounding the hole, until the sheet metal surrounding the hole has been substantially returned to a desired surface shape.

Referring now toFIGS. 1 and 3, views of the sheet metal straightening apparatus of the invention001are depicted in which the invention is disposed in a closed state in which moving jaw106and moving anvil105have been motivated fully into a closed state.FIG. 1depicts an embodiment of the hole straightening apparatus of the invention from a side perspective view.FIG. 3depicts an embodiment of the hole straightening apparatus of the invention from a rear perspective view. In the closed state as depicted inFIGS. 1 and 3, handle101has been motivated in the direction of arrow A towards frame100about pivot point120(depicted inFIG. 5). Pivot point120may comprise a cylindrical pin, axle, screw, shoulders screw or other substantially cylindrical element that allows the rotation of pivot handle100about moving jaw106at pivot point120. The operation of the hole straightening apparatus in transitioning from an open state to a closed state, and vice versa, is more fully described below in relation toFIG. 5. Stationary jaw108may be attached to frame100by mechanical attachments107. Mechanical attachments107may take any form known in the art such as threaded fasteners, press pins, rivets, or any other means for attaching one mechanical component to another. In embodiments, mechanical attachments107may easily removable with or without tools, such as, by way of example and not by way of limitation, threaded fasteners, pins having retaining features such as Cotter pins, spring loaded ball detent arrangements, or the like, in order to allow stationary jaw108to be removably attached to frame100. Such removable attachment of stationary jaw108to frame100enables the stationary jaw108and stationary anvil104to be removed and replaced by other embodiments of stationary jaw108and stationary anvil104in which stationary anvil104width W (not shown inFIG. 1, but shown inFIG. 7) is adapted to pass through openings Y of varying width forming a part of hole201in a sheet metal structure to be straightened200(not depicted inFIG. 1but depicted inFIGS. 11 and 12). In this manner stationary jaw108and stationary anvil104may be fabricated in any number of interchangeable embodiments in order to adapt the invention to various size holes201or to adapt the invention to various configurations of sheet metal structures to be straightened. In embodiments, mechanical attachments107may take the form of permanent attachments such as weldments, chemical bonding or any other means of attachment. Stationary jaw108may be attached to a stationary anvil bracket113to which stationary anvil104is attached. Stationary anvil bracket113and stationary anvil104may, but do not necessarily, form a unitary structure. In embodiments, stationary anvil bracket113and stationary anvil104may be formed from a single portion of sheet material. Moving anvil surface F and stationary anvil surface E are depicted for reference. Pivot points111and102are depicted for reference.

Referring now toFIGS. 2 and 4, views of the sheet metal straightening apparatus of the invention001are depicted in which the invention is disposed in an open state in which moving jaw106and moving anvil105have been motivated fully into an open state, i.e., in a direction away from stationary anvil104.FIG. 2depicts an embodiment of the hole straightening apparatus of the invention from a side perspective view.FIG. 4depicts an embodiment of the hole straightening apparatus of the invention from a rear perspective view. In the open state as depicted inFIGS. 2 and 4, handle101has been motivated in the direction of arrow A away from frame100about pivot point120(depicted inFIG. 5). Pivot point120may comprise a cylindrical pin, axle, screw, shoulder screw or other mechanical element, which may be, but is not necessarily, cylindrical, that allows the rotation of pivot handle100about moving jaw106at pivot point120. The operation of the hole straightening apparatus001in transitioning from a closed state to an open state, and vice versa, is more fully described below in relation toFIG. 5. Stationary jaw108may be attached to frame100by mechanical attachments107. Mechanical attachments107may take any form known in the art such as threaded fasteners, press pins, rivets, or any other means for attaching one mechanical component to another. In embodiments, mechanical attachments107may take the form of permanent attachments such as weldments, chemical bonding or any other means of attachment. Stationary jaw108may be attached to stationary anvil bracket113to which stationary anvil104is attached. Stationary anvil bracket113and stationary anvil104may, but do not necessarily, form a unitary structure. In embodiments, stationary anvil bracket113and stationary anvil104may be formed from a single portion of sheet material. Moving anvil surface F and stationary anvil surface E are depicted for reference. Pivot points111and102are depicted for reference.

Referring now toFIGS. 5 and 6, a side view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention001in an open state, in which the moving anvil105has been fully motivated away from the stationary anvil104of the invention of the invention, is depicted. In the open state, stationary anvil104may be motivated and articulated such that it is able to pass through a hole201in a deformed sheet metal structure200(seeFIGS. 8 and 10) for which straightening is desired. Stationary anvil104may have a width W that is smaller than a dimension of the hole201located in the sheet metal structure200for which straightening is desired. Thus, stationary anvil104may be articulated such that it may be motivated through the hole in the sheet metal structure as depicted further inFIGS. 8 and 10. Stationary anvil104, stationary anvil bracket113, and stationary jaw108may be fabricated as separate components and assembled by any means known in the art such as welding, chemical bonding, riveting, threaded fastener's, or the like; or, alternatively, stationary anvil104, stationary anvil bracket113and stationary jaw108may be a unitary structure fabricated by any means known in the art such as, for example and not by way of limitation, casting, molding, machining, additive manufacturing or any other means and method of manufacture. In an embodiment, stationary jaw108and stationary anvil104may each be fabricated from bent sheet-metal and welded or bonded together. Likewise, moving anvil105and moving jaw106may be a unitary structure fabricated by any means known in the art such as, for example and not by way of limitation, casting, molding, machining or any other means and method of manufacture. In an embodiment, moving jaw106may be fabricated from sheet metal. In an embodiment, moving anvil105may be fabricated by any means known in the art such as, for example and not by way of limitation, casting, molding, machining or any other means and method of manufacture. Stationary jaw108may be attached to frame100by attachments107as herein before described. Handle101may be rotably attached to lever112at attachment point111. When handle101is motivated towards frame100as shown by arrow A such that the hole straightening device of the invention001is transitioned to a closed state (seeFIG. 6for a depiction of the closed state), the pivoting action at pivot points111and120cause moving a jaw106to be motivated in the direction of arrow B towards stationary anvil104and stationary anvil surface E as moving jaw106slides along surface P of frame100in a sliding engagement. When handle101is motivated away from a frame100as shown by arrow A such that the sheet metal straightening of the device of the invention001is transitioned to an open state as shown inFIG. 5, and the pivoting actions at points111and120cause moving jaw106to be motivated in the direction of arrow B away from stationary anvil104and stationary anvil surface E as moving jaw106slides along surface C of frame100in a sliding engagement.

Still referring toFIGS. 5 and 6, the invention100may further comprise a threaded compression force adjusting rod109that may be threadingly engaged300with a portion of frame100and protruding into frame100, wherein a distal surface G of the threaded compression force adjusting rod may be in contact with a surface of lever112that is pivotally attached to handle101at pivot point111such that when threaded compression force adjusting rod109is rotated so as to protrude further into frame100, the compressive force between moving anvil surface F and stationary anvil surface E, or between moving anvil surface F, an intervening sheet structure to be straightened200, and stationary anvil surface E, is increased to a desired level when the hole straightening apparatus is in a closed state, and when the threaded compression force adjusting rod109is rotated so that the distal surface G of compression force adjusting rod109proceeds further out of the frame, the compressive force between moving anvil surface F and stationary anvil surface E is decreased when the hole straightening apparatus is in a closed state. InFIG. 6, a side view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention001in a closed state, in which moving anvil105has been fully motivated towards stationary anvil104of the invention of the invention, is depicted. Threaded compression force adjusting rod109may comprise a knurled knob110. In this manner, a user may adjust the amount of force used to straighten a sheet structure to be straightened200that is captured between moving anvil surface F and stationary anvil surface E when the invention is in a closed state by rotating threaded compression force adjusting rod109in its threaded engaged with frame100so as to translate distal surface G of compression force adjusting rod109further into frame100(increasing the compressive force on sheet structure to be straightened200), or rotating threaded compression force adjusting rod109in its threaded engaged with frame100so as to translate distal surface G of compression force adjusting rod109further out of frame100(decreasing the compressive force on sheet structure to be straightened200).

Referring now toFIG. 7, an exploded view of non-limiting exemplary embodiment of the invention is depicted. Stationary anvil104, stationary anvil bracket113, and stationary jaw108may be attached to frame100at attachment points107. Moving jaw106may be rotably attached to pivot point120of handle101. Handle101may be attached to lever112at pivot point111. Threaded compression force adjusting rod109may be threadingly engaged with, and protrude into, frame100.

Referring now toFIG. 8, a side view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention001, in which hole straightener001is being used to straighten the deformed edges of a hole201in a sheet-metal structure to be straightened200, is depicted. Moving anvil105has been motivated towards the stationary anvil104, capturing the deformed edges of deformed sheet metal around hole201between moving anvil surface F and stationary anvil E such that continued applied compressive force by the moving anvil against the deformed sheet-metal structure, resisted by the stationary anvil, as handle101is motivated towards frame100tending to transition hole straightener to a closed state, causes the deformed sheet-metal structure to be returned to a substantially non-deformed state. In this manner the disfigured sheet metal surrounding hole201and sheet metal structure200is substantially conformed to a desired surface shape. The desired surface shape may be any shape. Although a flat planar surface is depicted in the figures of the drawings, it is within the claimed scope of the invention that the desired surface shape may be any three-dimensional surface shape.

Referring now toFIGS. 9-11, an exemplary deformed sheet metal surface200that is be desired to be straightened is depicted. Deformed sheet metal surface200may comprise a hole201defined by an opening dimension Y. It is not necessary that hole201be circular; thus hole201may be of any shape. Sheet metal structure200may be deformed to a maximum dimension from a desired surface shape by a dimension R in height, and by a dimension S in width. Stationary anvil104may be inserted through hole201and motivated against a side wall of hole201as shown inFIG. 10. InFIG. 10, the hole straightening apparatus of the invention001is depicted in an open state. Moving anvil surface F is motivated towards stationary anvil surface E in the direction of arrow B when handle101is motivated towards frame100as herein discussed in relation toFIGS. 1 through 6. When handle101is motivated towards frame100the hole straightening apparatus of the invention transitions towards a closed state, causing a compressive force to be applied by moving anvil surface F on the one hand, and stationary anvil surface E on the other hand, capturing a portion of sheet metal structure to be straightened200comprising deformity I between the two anvil surfaces E and F. The compressive force causes deformity I to be substantially straightened. In operation, the user then motivates the hole straightening apparatus of the invention001around the edge of the opening of hole201while sequentially operating handle101from an open state to a closed estate, causing a compressive force between anvil surfaces E and F on the sheet metal of structure200that surrounds hole201. Thus, an operator sequentially straightens the deformed sheet metal surrounding hole201and sheet metal structure to be straightened200by: 1) starting with the hole straightening apparatus of the invention001in an open state, inserting anvil104through hole201; 2) motivating anvil104towards an edge of hole201; 3) motivating handle101towards frame100causing a transition towards a closed state and thereby asserting a compressive force on the sheet-metal structure200captured between anvil surfaces E and F as hereinbefore described, 4) transitioning the hole straightening apparatus of the invention001into an open state by motivating handle101away from frame100; 5) motivating the sheet metal straightening device of the invention001along an edge of hole201to a next portion of deformed sheet-metal surrounding the opening of hole201and sheet-metal structure200to be straightened, and repeating steps 1) through 4). Steps 1) through 5) are then repeated until all of the deformed sheet metal surrounding the edge of the opening of hole201have been substantially straightened.FIG. 11depicts an initial view of a sheet metal structure200that has been subjected to disfiguring forces, causing deformities in the sheet metal surrounding hole201, and for which straightening is desired.FIG. 12depicts a final view of a sheet metal structure200that has been subjected to the above procedure for hole straightening, using the hole straightening apparatus of the invention001. InFIG. 12, the surface deformities surrounding hole201have been substantially removed from sheet metal structure200such that sheet-metal structure200has been substantially conformed to a desired surface shape.

Any of the described features may be present, in any combination, in any embodiment of the invention.