Abstract:
This document presents a system and method for presenting the invention as a tool that provides the ability to bend and shape rebar type material with less stress on the human body aiding in preventing common injuries that occur from standard rebar tools and processes and it provides portability so that all work can be done at the job site saving time and money from having to go to a workshop to fabricate unique shaped rebar parts.

Description:
COPYRIGHT NOTICE 
     A portion of the disclosure of this patent document contains material which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction of the patent document or the patent disclosure, as it appears in the Patent and Trademark Office patent file or records, but otherwise reserves all copyright rights whatsoever. 
     BACKGROUND 
     Concrete construction is enhanced by the insertion of metal rods such as rebar to improve compression and tension characteristics of the concrete structure. To accommodate joins, curves, and other structural elements, rebar must be shaped prior to installation to support the structural components of the concrete structure. Many rebar structural pieces are shaped prior to shipping them out to a job site, if the job is big enough to permit the builder to bear the cost of ordering pre-shaped rebar. Other construction jobs are either too small to bear this cost, or the shapes required are either too complex or unknown, or the builder simply does not want to bear this cost and will bend the rebar on site to suit the needs of the construction effort. 
     Bending rebar for emplacement in concrete at a construction site is a common practice. Tools for bending rebar are generally makeshift or simple in nature and construction crews depend on brute force to utilize the tools for bending rebar. Bending rebar may place significant strain on the muscles in the upper and lower back, and cause damage to a construction crewman when the tool is inadequate to the job or is used improperly. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Certain illustrative embodiments illustrating organization and method of operation, together with objects and advantages may be best understood by reference to the detailed description that follows taken in conjunction with the accompanying drawings in which: 
         FIG. 1  is an exploded view of all individual components of a rod bending tool consistent with certain embodiments of the present invention. 
         FIG. 2  is a view of the upper surface of a rod bending tool consistent with certain embodiments of the present invention. 
         FIG. 3  is a view of the underside of a rod bending tool consistent with certain embodiments of the present invention. 
         FIG. 4  is a right side view of a rod bending tool consistent with certain embodiments of the present invention. 
         FIG. 5  is a view of the back side of a rod bending tool consistent with certain embodiments of the present invention. 
         FIG. 6  is a view of a view of a rod bending tool attached to a mounting adaptor in operational configuration consistent with certain embodiments of the present invention. 
         FIG. 7A  is a view of a view of a rod bending tool attached to a mounting adaptor in a horizontal operational configuration consistent with certain embodiments of the present invention. 
         FIG. 7B  is a view of a view of a rod bending tool attached to a mounting adaptor in a vertical operational configuration consistent with certain embodiments of the present invention. 
         FIG. 7C  is a view of a view of a rod bending tool attached to a mounting adaptor in a center position operational configuration consistent with certain embodiments of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     While this invention is susceptible of embodiment in many different forms, there is shown in the drawings and will herein be described in detail specific embodiments, with the understanding that the present disclosure of such embodiments is to be considered as an example of the principles and not intended to limit the invention to the specific embodiments shown and described. In the description below, like reference numerals are used to describe the same, similar or corresponding parts in the several views of the drawings. 
     The terms “a” or “an”, as used herein, are defined as one or more than one. The term “plurality”, as used herein, is defined as two or more than two. The term “another”, as used herein, is defined as at least a second or more. The terms “including” and/or “having”, as used herein, are defined as comprising (i.e., open language). The term “coupled”, as used herein, is defined as connected, although not necessarily directly, and not necessarily mechanically. 
     Reference throughout this document to “one embodiment”, “certain embodiments”, “an embodiment” or similar terms means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearances of such phrases or in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments without limitation. 
     The term “rod bending tool” in this document refers to a tool that is used for bending concrete reinforcing rods, also known as rebar, for use in concrete construction. The rod bending tool is also suitable for bending additional reinforcing metal rods such as square stock, round stock and flat stock. 
     In an embodiment, the rod bending tool used for bending concrete reinforcing rods (re-bar) may be designed to perform bending tasks at a particular height and in a particular position to prevent hazards and injuries to construction crewmen that commonly occur while performing this task. The rod bending tool is a portable device that may be transported to a construction site and used as needed during construction. 
     Previously known Re-bar bending tools are manually operated tools placed on the ground, where the earth is used as the frame and backing for the operator to push against for bending the stock. The bending is done utilizing a user&#39;s own body weight as leverage to force the rebar to bend. Performing this task with the rebar bending tool at ground level has potential to cause a user injuries resulting from the repetitive strain of bending, stooping and pulling on the metal rod, whether the rod is rebar, square stock, round stock, flat stock, or any other type of metal or non-metal reinforcing rod. Tools for bending rebar type material designed to be fitted to a truck are also known and available. However, these tools are mounted such that the work piece is too high for a user to bend without difficulty, where there may be a lack of leverage to bend the rebar at certain necessary angles, and where the positioning of the tool may result in repetitive stress injuries to the workers. 
     Additionally, current and existing methods and tools lack portability. For instance it is impossible for operators to fabricate unique specialty rebar parts on site with existing tools and methods. Thus, unique specialty rebar parts, or custom shaped rebar parts suited to a unique circumstance at a job site, may have to be manufactured in a factory or specialty bending facility at additional cost. The special requirements for unique specialty rebar parts may also cause construction delays if the need is discovered during construction, or the fabricating entity requires long lead times to fulfill such orders. 
     The rod bending tool herein disclosed may help solve these issues by providing users a portable means to bend the material with a secure and safe positioning without requiring the human worker to use his/her body for leverage during a bending action. The rod bending tool is portable, allowing operators to fabricate unique and specialty rebar parts anywhere, such as a construction site, home site, garage or other location, rather than in the shop or factory. The rod bending tool has a specially designed frame upon which the rod bending tool may be mounted. The mounting frame may be securely attached to a vehicle. The mounting frame may provide various angles for the rod bending tool to be configured, which establishes the work space for the rod bending tool at a comfortable height above the ground level. The mounting frame also provides flexibility when attached to a workhorse or a table, creating an additional work space. The rod bending tool and mounting frame provide the leverage to bend the rebar or other metal type material, not utilizing a human body and the earth for leverage. The rod bending tool may thus help eliminate the existing problems of having insufficient leverage to perform some bends out in the field that occur with current standard tools and methods for bending rebar type material. 
     Additionally, the rod bending tool allows the operator to bend any type of rod stock material while standing upright without having to bend, stoop or reach excessively. This advantageous positioning may prevent injuries that commonly occur with standard existing tools and methods. 
     Turning now to  FIG. 1 , this figure presents an exploded view of a rod bending tool  100  consistent with the certain embodiments of the present invention. In an exemplary embodiment, the rod bending tool  100  may have a base plate  102  having a horizontal portion  104  and the vertical portion  106  connected together at approximately a 90 degree angle. In an alternative embodiment, the base plate  102  may be formed from a section of angle iron having the proper angle between the horizontal portion  104  and the vertical portion  106 . The horizontal portion  104  may have a rounded end  108  for the connection to both a fulcrum  110  and a flat lever  118 . The fulcrum  110  may be permanently mounted to the base plate  102 . 
     In this embodiment, the base plate horizontal portion  104  may have a positioning hole  124  provided at the desired location for the fulcrum  110  to be inserted through and centered. The fulcrum  110  may be cut to fit and centered through the positioning hole  124 . The fulcrum is held in position relative to the base plate  102  through the connection of a pivot shaft  112  and brass washer  114 . The brass washer  114  is positioned on the pivot shaft  112  and acts as a thrust washer between pivot shaft  112  and a round roller  116 . 
     Additionally, the pivot shaft  112  and brass washer  114  are positioned to permit free horizontal movement of the flat lever  118 . To provide proper alignment and use, the pivot shaft  112  may be inserted through the positioning hole  124  cut in the fulcrum  110 , and extend past the bottom surface of the horizontal portion  104  of the base plate  102 . 
     In this exemplary embodiment, the pivot shaft  112  may be inserted through a thick brass thrust washer  120  may be positioned between the bottom surface of the horizontal portion  104  of the base plate  102  and the top surface of the flat lever  118 . The brass thrust washer  120  provides for separation between the base plate  102  and the flat lever  118 , and permits rotational movement of the flat lever  118  as the base plate  102  remains stationary. 
     A bend shaft  122  is physically connected to the flat lever  118 , but is not physically connected to the base plate  102 . The bend shaft  122  and pivot shaft  112  may be used in conjunction to permit more complex rotational movement than is possible with a single pivot shaft  112 . The bend shaft  122  is connected to the flat lever  118  and may permit rotational movement  122  to bend rebar separate from the pivot shaft  112 . The bend shaft  122  may be inserted through a brass washer  132  and into a hole drilled in the center of a round roller  116 . 
     In this exemplary embodiment, the round roller  116  is essential in guiding the material that will be bent by the fulcrum  110 . The round roller  116  is permanently attached to the top surface of the flat lever  118  by inserting and centering the bend shaft  122  through holes drilled through a brass thrust washer  132  and steel spacer  136 . The holes drilled through the brass washer  132 , round roller  116 , brass thrust washer  132  and steel spacer  136  are each aligned to permit the bend shaft  122  to be inserted and connected to each of these portions to create the bend assembly that is attached to the flat lever  118 . 
     The bottom ends of the pivot shaft  112  and bend shaft  122  are centered through holes ( 150 ,  152 ) and permanently attached to the flat bar or lever  118 . The flat lever  118  is contoured on the pivot shaft  118  end and tapered at the bend shaft  122  end. The flat lever  118  is positioned below the horizontal portion  104  of the base plate  102 , and provides the ability to physically manipulate the rebar stock during bending operations. 
     Attached parallel to the top surface of the flat lever  118  and adjacent along the same plane as the base plate  102  is a fixed round stock handle  128  which is permanently affixed to and extends past the flat lever  118 . The round stock handle  128  may be rounded on both ends. The round stock handle  128  provides a grip and a longer lever arm for greater leverage for the user when performing the task of bending rebar or other rod stock material. A cap  138  is centered on top of both the fulcrum  110  and the round roller  116  to prevent foreign material dirt and debris from getting into the assembly. In non-limiting examples, the cap  138  may be substantially flat or may have a rounded top to better reduce the amount of debris that could adhere to the pivot shaft  112  and bend shaft  122 . 
     In this exemplary embodiment, a mounting tube  140  may be attached to the bottom surface of the horizontal portion  104  of the base plate  102 . The mounting tube  140  is used to attach the rod bending device directly to a post, frame, trailer hitch or vehicle, or to any additional support apparatus that may then be attached to a post, frame, vehicle, or trailer hitch. In this exemplary embodiment a standard trailer hitch pin may be used to hold the mounting adapter securely in place. 
     Turning now to  FIG. 2 , this figure presents a view of the upper surface of a rod bending tool  200  consistent with certain embodiments of the present invention. In an exemplary embodiment, the rod bending tool  200  may consist of a bending handle  202  permanently bonded to a flat lever  204 . A bend shaft  206  is connected to the flat lever  204  and forms a holding and bending point for metal bending stock on the flat lever  204 . The flat lever  204 , bending handle  204  and bend shaft  206  form the movable portion of the rid bending tool  200 . The base plate  208  is connected to the flat lever  204  at a pivot shaft  210 . The pivot shaft  210  forms an interconnection point with the flat lever  204  such that when a user applies force to the flat lever  204  by grasping and either pushing or pulling the bending handle  202 , the pivot shaft  210  permits the flat lever  204  to move in a horizontal plane with respect to the base plate  208 . The pivot shaft  210  permits the flat lever  204  to traverse approximately 270 degrees of angle with respect to the base plate  210 . 
     In this exemplary embodiment, when in operation, a metal stock rod may be inserted between the pivot shaft  210  and the bend shaft  206 . In this embodiment, the bend shaft  206  may act as the fulcrum around which the rod stock material is bent to the desired shape or angle. The flat lever  204 , upon which the bend shaft is installed, may be opened or closed to any desired angle, again with relation to the base plate  210 , to permit the required initial position for insertion of the rod stock to be manipulated. The user may then apply force to the bending handle  202 , either pushing or pulling the bending handle  202 , while the rod stock is held in place by the base plate  208 . The pivot shaft  210  and bend shaft  206  form the bending points for the rod stock inserted in to the tool, permitting a user to form bends in the inserted rod stock as desired to meet the needs of a construction project on site. 
     In this exemplary embodiment, the rod bending tool  200  assembly may be connected to an optional mounting adapter  212 . The mounting adapter is attached to the rear side of a mounting tube  214 . The mounting adapter  212  may be attached to an external mounting tube  216 , which may be connected to support apparatuses such as a stand-alone frame, a vehicle, or a trailer hitch associated with a vehicle. The external mounting tube  214  is attached to a support apparatus to permit the rod bending tool  200  to be placed in a vertical position and at a vertical height that is most comfortable for the user, minimizing strain and injuries from the use of the rod bending tool  200 . 
     Turning now to  FIG. 3 , this figure presents a view of the underside of a rod bending tool  300  consistent with certain embodiments of the present invention. In an exemplary embodiment, the optional mounting tube  302  is depicted being attached to the back side of the mounting tube  304 . The mounting tube  304  is of sufficient dimension to permit the rod bending tool  300  to be slideably attached to the mounting adaptor  306 . The mounting adaptor  306  may have multiple attachment points and vertical positions to permit the rod bending tool to be attached to the mounting adaptor  306  in any of a multitude of positions prior to use of the rod bending tool. 
     Turning now to  FIG. 4 , this figure presents a view of right side view of a rod bending tool  400  consistent with certain embodiments of the present invention. In an exemplary embodiment, it is clear that the proximate and distal ends of the bending handle  402  are rounded to prevent a user from coming to harm from inadvertently grasping one end or the other. The bend shaft  404  and pivot shaft  406  may be aligned in any position along the arc of travel of the flat lever  408  to facilitate both the insertion of and bending of rod stock. The base plate vertical section  410  forms a wall for the leverage in bending operations, and for retention of rod stock between the pivot shaft  406  and the base plate vertical section  410 . 
     In this exemplary embodiment, the rod bending tool  400  may be positioned in a vertical orientation or horizontal orientation to the ground through the use of the mounting adaptor  412 . In an exemplary embodiment, a horizontal mounting collar  414  may be slideably connected to the mounting adaptor  412  to permit the insertion of rod stock in a vertical orientation to the ground. In an alternative embodiment, a vertical mounting collar  416  permits a connection to the mounting adaptor  412  that permits the insertion of rod stock in a horizontal orientation to the ground. 
     In this exemplary embodiment, the mounting adaptor  412  is connected through a 90 degree join  418  to a horizontal support element  420 . The horizontal support element  420  is of sufficient length and made of sufficient strength material to permit the attachment to a frame, vehicle, or trailer hitch associated with a vehicle, permitting the transportation and use of the rod bending tool  400  at construction and other sites remotely located from a shop or rod stock manufacturer. 
     Turning now to  FIG. 5 , this figure presents a view of the back side of a rod bending tool consistent with certain embodiments of the present invention. In an exemplary embodiment, the rod bending tool  500  may have a pivot shaft  502  having a non-circular shape. The pivot shaft  502  may have a rounded tear drop shape with the narrow section placed so as to permit the narrow section to face the bend shaft (not visible) when the rod bending tool  500  is in operation. The proximate end of the base plate  504  may also be cut off at an angle with relation to the base plate  506  to permit a greater degree of movement of the flat lever portion with relation to the base plate  506  when rod stock has been inserted into the rod bending tool  500 . The rounded tear drop shape of the pivot shaft  502  also may permit greater flexibility in the angles of bends and types of bends that can be performed by the tool when in operation. 
     Turning now to  FIG. 6 , this figure presents a view of a rod bending tool attached to a mounting adaptor in operational configuration consistent with certain embodiments of the present invention. In this exemplary embodiment, the rod bending tool  600  may have horizontal mounting tube  602  and vertical mounting tube  604  portions permanently attached to the rod bending tool  600 . The horizontal mounting tube  602  and the vertical mounting tube  604  are attached in a perpendicular orientation to one another. This attachment permits the rod bending tool  600  to be slideably attached to the mounting adaptor in an orientation that permits either a vertical orientation or a horizontal orientation for rod stock being inserted into the rod bending tool  600 . This flexibility of orientation permits a user to adjust the rod bending tool  600  to carry out bends in rod stock that require orientations different than simply horizontal. 
     In this exemplary embodiment, the mounting adaptor  606  may have one or more adjustable horses arms  608  that permit the support of rod stock as it is undergoing bending operations. The adjustable horses  610  are removably attached to the mounting adaptor  606  through the use of an adjustable horses mounting tube  612 . In this embodiment, the mounting adaptor  606  may be attached to a vehicle, frame, or trailer hitch for use in the field. Additionally, the mounting adapter  606  is collapsible and may be folded for easy storage and transport. 
       FIG. 7A  is a view of a view of a rod bending tool attached to a mounting adaptor in a horizontal operational configuration consistent with certain embodiments of the present invention. In this exemplary embodiment, the rod bending tool is removably attached to an end of the mounting adaptor. The mounting adaptor is a hollow collar that permits the rod bending tool to be slid onto the end of the mounting adaptor in an orientation that places the bend and pivot shafts and the bending handle in a horizontal orientation to the ground at a construction site. This permits a user to insert a section of rod stock to be bent into the rod bending tool in the horizontal plane and permits the user to apply force in the horizontal plane to effect bends required. In this orientation, the rod stock may be supported by the adjustable horse arms as the bending operation is performed, permitting a single user to perform bending actions on very long sections of rod stock without assistance. The horizontal orientation permits the user to stand upright and pull or push toward or away from the center of the user&#39;s mass to apply force, reducing strain and injury to the user from repetitive bending actions. 
       FIG. 7B  is a view of a view of a rod bending tool attached to a mounting adaptor in a vertical operational configuration consistent with certain embodiments of the present invention. In this exemplary embodiment, the rod bending tool is removably attached to an end of the mounting adaptor. The mounting adaptor is a hollow collar that permits the rod bending tool to be slid onto the end of the mounting adaptor in an orientation that places the bend and pivot shafts and the bending handle in a vertical orientation to the ground at a construction site. This permits a user to insert a section of rod stock to be bent into the rod bending tool in the vertical plane and permits the user to apply force in the vertical plane to effect bends required. The vertical orientation permits the user to stand upright and pull or push toward or away from the center of the user&#39;s mass to apply force, reducing strain and injury to the user from repetitive bending actions. 
       FIG. 7C  is a view of a view of a rod bending tool attached to a mounting adaptor in a center position operational configuration consistent with certain embodiments of the present invention. In this exemplary embodiment, the rod bending tool is removably attached to a middle portion of the mounting adaptor. The mounting adaptor is a hollow collar that permits the rod bending tool to be slid onto the end of the mounting adaptor in an orientation that places the bend and pivot shafts and the bending handle in a horizontal orientation to the ground at a construction site. This permits a user to insert a section of rod stock to be bent into the rod bending tool in the horizontal plane and permits the user to apply force in the horizontal plane to effect bends required. In this orientation and position, the adjustable horse arms may be positioned closer to or further away from the rod bending tool to permit support for the rod stock on either side of the rod bending tool during bending operations. The horizontal orientation permits the user to stand upright and pull or push toward or away from the center of the user&#39;s mass to apply force, reducing strain and injury to the user from repetitive bending actions. 
     While certain illustrative embodiments have been described, it is evident that many alternatives, modifications, permutations and variations will become apparent to those skilled in the art in light of the foregoing description.