Abstract:
Apparatus for storing and dispensing portions from a bulk roll of carpet. The apparatus is portably mounted in a vehicle or the like and telescopically extends from the vehicle in position for the dispensing measured portions of the carpet from the roll, following which the apparatus is telescopically returnable to the vehicle for storage, transport or the like.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This Application claims the benefit of U.S. Provisional Application No. 60/665,501, filed Mar. 25, 2005. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not Applicable  
       FIELD OF INVENTION  
       [0003]     This invention relates to apparatus and methods-for dispensing a large roll of carpet (known in the art as “bulk roll”) in manageable portions suitable for covering a given area of flooring.  
       BACKGROUND OF THE INVENTION  
       [0004]     Commonly in the art, carpet floor covering is purchased in bulk rolls, each of which individually weighs more than that weight which is reasonably manually manipulated. Such bulk rolls most commonly require a forklift or other mechanical apparatus for moving the roll into and out of storage. The advantage of a forklift is not commonly available at a job site where the bulk carpet is to be divided into portions, each of a size suitable for application of the carpet onto a given area for flooring.  
         [0005]     Bulk carpet commonly is available in twelve foot widths. The amount of carpet (length) in a roll may vary widely. It is not uncommon for a bulk roll of carpet to weigh several hundred pounds. Movement of a roll of this nature from storage and transport of the same to a job site almost universally requires some type of mechanical lift, such as a forklift for moving the roll from storage and only a truck, van or the like for transport to the job site. Transporting of a forklift, for example, to a job site is not practical, however, thereby creating a problem for an installer when reaching the job site.  
         [0006]     At a job site, the carpet installer must divide the twelve foot wide carpet into individual portions, each having a length which is suitable for covering a given area of flooring. For example, for covering a 12×12 foot floor area, the installer will need to unwind 12 linear feet of the carpet from the roll, etc. In most instances, multiple withdrawal of individual portions of the bulk roll will be made with respect to a given job site.  
       BRIEF SUMMARY OF THE INVENTION  
       [0007]     In accordance with the present invention there is provided an apparatus which is itself mounted in a vehicle such as a truck, van or the like, hence is portable, and which may be loaded with a bulk roll of carpet from storage, for example, transported to a job site, and which is extensible, at the job site, from its original stored length within the vehicle to a “working” length external of the vehicle.  
         [0008]     Multiple sets of rails mounted mutually telescopically with respect to one another carry demountable structure for receiving a bulk roll of carpet, for storage of the bulk roll during transport to a job site, for measuring off a desired length of carpet from the roll, and for retaining the remainder of the roll stored for future use, if needed. Manual manipulation of the bulk roll itself for reasons other that unrolling desired portions thereof, are effectively eliminated, thereby allowing one or two persons to easily and readily withdraw desired portions of the length of the carpet from the bulk roll. Such portions are readily manually moved from the present apparatus to the location where they are to be laid over a given area of flooring.  
         [0009]     In one embodiment, demountable structural components are provided for various subassemblies of the apparatus of the present invention.  
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0010]      FIG. 1  is a representation of an apparatus embodying various of the features of the present invention associated with a vehicle and showing the apparatus in its extended attitude and with a bulk roll of carpet mounted thereon;  
         [0011]      FIG. 2  is perspective view of triple rail sets of an apparatus of the present invention telescopically extended and showing a bulk roll of carpet in phantom;  
         [0012]      FIG. 3  is an exploded view of the triple rail sets depicted in  FIG. 2 ;  
         [0013]      FIG. 4  is an exploded view of several demountable components of one embodiment of various subassemblies of the apparatus of the present invention associated with the most outboard one of the extended rail sets of an apparatus of the present invention;  
         [0014]      FIG. 5  is an exploded view of one embodiment of a central, rail mounted, support for a bulk roll of carpet mounted on the most outboard one of the extended rail sets of an apparatus of the present invention;  
         [0015]      FIG. 6  is a representation of a portion of the outboard end of the most outboard one of the triple rail sets of an apparatus of the present invention;  
         [0016]      FIG. 7  is a representation of a portion of the inboard end of an apparatus of the present invention in its extended attitude; and,  
         [0017]      FIG. 8  is a detail view of one embodiment of a track mounted central support of a bulk roll of carpet mounted on the most outboard rail set of an apparatus of the present invention and depicting details of roller supports for the telescoping rail sets and roller supports for the central support for a bulk roll of carpet mounted on the apparatus of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0018]     With initial reference to  FIGS. 1 and 2 , in one embodiment, the present invention includes at least two, and preferably, first, second and third telescoping rail sets  12 ,  14  and  16 , respectively, the first rail set  12  being fixedly mounted in the bed  16  of a vehicle  22  of a size suitable to receive and enclose a bulk roll of carpet  24  of the common twelve foot width, or a bulk roll of greater or lesser width carpet. The vehicle employed may be of any suitable type, such as a truck, van or trailer. Preferably, the vehicle is enclosed to provide protection for the carpet from the elements. For purposes of economy of space utilization, the vehicle preferably is of a rectangular floor plan, with the length of the floor running parallel to the intended direction of travel  26  of the vehicle.  
         [0019]     In the depicted embodiment the apparatus includes a first rail set  12  which is designed to be rigidly affixed to the floor  28  of the vehicle in which the apparatus is housed. The apparatus further includes a second rail set  14  which is telescopically mounted in the first rail set. To this end, the first and second rails  29  and  31 , respectively, of the first rail set are each in the form of first and second “C” channels  30 ,  32 , preferably of a metal, the openings  34 ,  36  of which face one another across the width of the rail set. Side brackets  38  (typical) are affixed to the outside web  40 ,  42  of each “C” channel and provide means by which each of the first and second “C” channels of the first rail set may be bolted, or otherwise fixedly attached, to the floor of the vehicle. In the depicted embodiment, there are provided cross member braces  44 ,  46  and  48  extending between each of the respective opposite ends  50 ,  52  of the first and second “C” channels and approximately midway between such opposite ends which provide rigidity to the rail set and which aid in ensuring the required constant lateral spacing between the first and second rails of the set. Importantly, the first and second “C” channels of the first rail set are coplanar, extend parallel with one another and are plumb with respect to one another. In one example, the first and second “C” channels of the first rail set are spaced apart from one another by a distance of thirty-six inches outside to outside. No roller bearings are provided on the first rail set. Rather, each of the “C” channels is adapted to define a bearing raceway  58 ,  60 , respectively, for roller bearings  62  (typical) associated with a second rail set  14  which are received within such “C” channels. To expedite the receipt of such roller bearings therein, the top leg  64 ,  66  of each of the “C” channels is about one inch less in width than the bottom leg of such channel.  
         [0020]     In a typical example, each of the rails of the first rail set are about ten feet in length.  
         [0021]     As seen in  FIG. 3 , in the depicted embodiment, the second rail set also comprises first and second rails  68 ,  70  defined by first and second “C” channels  72 ,  74  which are substantially the same cross-sectional dimensions as the “C” channels of the first rail set. In the depicted embodiment, there are provided cross member braces  76 ,  78  extending between each of the respective opposite ends  89 ,  82  and  64 ,  86  of the first and second “C” channels  20 ,  29  for purposes of rigidity and constancy of lateral spacing of the rails of the second set. Importantly, the first and second “C”, channels are coplanar, extend parallel with one another and are plumb with respect to one another and with respect to the “C” channels of the first rail set. In one example, the first and second “C” channels of the second rail set are spaced apart from one another by a distance of thirty-one and one half inches outside to outside.  
         [0022]     For purposes of providing telescopic movement of the second rail set with respect to the first rail set, the openings of the first and second “C” channels  34 ,  36  of the first rail set face one another to define bearing raceways  58 ,  60  along the length of each of the first and second rails of the first rail set for receipt therein of roller bearings  62  of the second rail set.  
         [0023]     On the outside surface  88 ,  89  of the webs  92 ,  94  of each of the first and second “C” channels  72 ,  74  of the second rail set there is mounted a plurality of roller bearings  62  at spaced apart locations along the length of such first and second “C” channels of the second rail set. These roller bearings project outwardly from the outside surface of the web of the “C” channels of the second rail set and are operatively received within respective ones of the bearing raceways  58 ,  60  defined by the first and second “” channels of the first rail set thereby providing for precise and repetitive telescopic movement of the second rail set with the first rail set.  
         [0024]     For purposes of providing telescopic movement of the third rail set  16  with respect to the second rail set  14 , the openings  96 ,  98  of the first and second “C” channels of the second rail set face one another to define bearing raceways  100 ,  102  along the length of the rails of the second rail set for receipt therein roller bearings  62 ′ (typical) associated with the third rail set.  
         [0025]     As seen if  FIG. 3 , in the depicted embodiment, the third rail set  16  also comprises first and second “C” channels  104 ,  106  which are substantially the same cross-sectional dimensions as the “C” channels of the first and second rail sets and which define the first and second rails  120 ,  122  of the third rail set. In the depicted embodiment, there are provided cross member braces  108 ,  110  extending between each of the respective opposite ends of the first and second “C” channels of the third rail set for purposes of rigidity and constancy of lateral separation of the first and second rails of the third rail set. Importantly, the first and second “C” channels of the third rail set are coplanar, extend parallel with one another and are plumb with respect to one another and with respect to the “C” channels of the first and second rail sets. In one example, the first and second “C” channels of the third rail set are spaced apart from one another by a distance of twenty-seven and one half inches outside to outside.  
         [0026]     As with the rails  124 ,  136  of the second rail set, each of the web portions of each of the first and second “C” channels of the third rail set is provided with a plurality of roller bearings  62 ′with are receivable respective ones of the bearing raceways  98 ,  100  defined within the facing “C” channels of the second rail set. In a typical example, each of the rails of the third rail set are also about ten feet in length so that substantially the entire length of the third rail set is telescopically receivable within the first and second rail sets.  
         [0027]     On the outside surfaces  128 ,  130  of the webs  124 ,  126  of each of the first and second “C” channels of the third rail set, there are mounted a plurality of roller bearings  62 ′at spaced apart locations along the length of such first and second “C” channels of the third rail set. These roller bearings project outwardly from the outside surface of the web of the “C” channels of the third rail set and are operatively received within respective ones of the bearing raceways of the first and second “C” channels of the second rail set thereby providing for precise and repetitive telescopic movement of the third rail set with respect to the second rail set.  
         [0028]     In the depicted embodiment, each of the roller bearings is journaled on a stub shaft  132  which projects laterally from a respective web portion of each of the first and second rails of each of the second and third rail sets (See  FIG. 6 . In one example, each roller bearing is thus oriented in a vertical plane, with all of the roller bearings on a web of a given rail of a given rail set web being coplanar. As noted the lateral spacing between the first and second rails of the second rail set is about four inches less than the lateral spacing between the first and second rails of the first rail set. Further, the lateral spacing between the first and second rails of the third rail set is about 4.5 inches less than the lateral spacing between the first and second rails of the second rail set. By this means, the third rail set is telescopically receivable between the rails of the second rail set and the second rail set is receivable between the rails of the first rail set. In one example, the vertical clearance between the roller bearings and the vertical height of a respective raceway is about 0.0625 inch, thereby ensuring that when the three rail sets are telescopically fully received within one another the three rails sets occupy a common plane. By reason of the precise dimensioning of the components of the three rail sets, this commonality of planar orientation of the three rail sets is maintained even when the rail sets are each fully telescopically extended with respect to each other.  
         [0029]     Maintenance of the coplanar orientation of the three rails sets is further ensured by means of one or more jacks  134 , 136  mounted on and adjacent the outboard ends  84 ,  86  of each of the first and second rails of the second rail set. Like jacks  138 ,  140  are mounted on and adjacent the outboard ends of the first and second rails of the third rail set. Each jack is demountable for purposes of telescopic retraction of the third rail set into the second rail set and retraction of the combined second and third rail sets into the first rail set. As desired, each jack may be provided with an omnidirectional wheel  141  as an aide in sliding movement of the second and third rail sets between their telescoped and extended positions. Demountability of each jack may be provided by means of at least two spaced apart bolts, for example (not shown), which extend through respective throughbores of each jack and through registering throughbores through a respective rail and with suitable locking nuts applied to the distal ends of such bolts or other suitable pinning and/or locking device as is known in the art.  
         [0030]     In a preferred embodiment, further safety pins  142  (typical) are inserted through registering throughbores of each jack and both of the rails of the adjacent telescoping rails of the second and third rail sets when the second and third rail sets are extended with respect to the first rail set and with respect to one another. These same safety pins may be employed to retain the multiple rail sets in their contracted telescopic relationship, as desired. Preferably, for safety reasons, these safety pins are color coded with a paint which strongly contrasts with the color of the rails of the multiple rail sets.  
         [0031]     With reference to  FIGS. 2,3  and  6 , as depicted, there is fixedly mounted on the top leg  144 , 146  of each of the first and second rails of the second rail set, individual inverted “v” rails  148 , 150  that extend along the length of their respective rail. Like inverted “v” rails  152 ,  154  are mounted on the top legs  156 , 158  of each of the first and second rails of the third rail set. Each such inverted “v” rail is adapted to receive thereon the circumferentially “v” notched wheels  160  (typical) (See  FIG. 8 ) of one or more dollies for reciprocating movement of the dollies along the length of respective ones of the second and third rail sets.  
         [0032]     In particular, in accordance with one aspect of the present invention, support for a bulk roll of carpet is provided by a first demountable dolly which is mounted for reciprocating movement along the length of the second rail set by means of circumferentially “V” grooved wheels which ride along the inverted “v” rails mounted on the top of each of the first and second rails of the third rail set. Designated as the inboard (first) dolly  162 , this dolly includes a generally planar platform  164  having a top surface  166  on which there is removably mounted a first standard  168  which extends upwardly from the top surface  166  and obliquely laterally away from the general centerline  170  of the apparatus of the present invention. This standard may take the form of a polymeric tube  172 , one end  174  of which is removably received within a 45-degree polymeric elbow  176  which, in turn, is affixed at one of its ends  178  to the top surface of the dolly. Thus, this standard is removable from the dolly when not in use. Moreover, as desired, the dolly may also be removed from its supporting rails, as needed or desired. Being rollably mounted on the first and second rails of the third rail set, this first dolly is movable along substantially the entire length of the third rail set.  
         [0033]     On the outboard end of the standard, there is provided a tee  180  which also is removable from the standard as desired, The cross leg  182  of the tee is oriented horizontally and slidably receives therethrough an inboard end  104  of a first polymeric rollup tube  186  which is adapted to receive a portion of carpet rolled thereupon. The opposite end  188  of the first tube  186  is slidably received within a second polymeric rollup tube  100  which extends from the first tube to an outboard (second) dolly  192 . The inboard end  194  of this second tube is rotatably and slidably received with the cross leg  196  of a further tee  198  which, in turn is mounted on a second standard  200  that is removably mounted in a 45-degree elbow  202  affixed to the top surface  204  of the second dolly  192  and extends upwardly and obliquely outwardly from the top surface of the second dolly. The first and second tubes may rotate together, as by a frictional fit therebetween, but are slidable with respect to one another to permit selection of the overall length of the first and second tubes.  
         [0034]     This second dolly is rollably mounted on the inverted “v” rails that are mounted on the top surface of the first and second rails of the second rail set hence is movable along substantially the entire length of the second rail set.  
         [0035]     There is fitted a wheel  208  on the outboard end  206  of the first tube that is mounted on the first dolly, such wheel being pinned to the first tube so that rotation of the wheel effects rotation of the first and second tubes, substantially simultaneously. As noted, the first tube is inserted into the second tube thereby providing for selection of the overall effective length of the two combined tubes by moving the first and second dollies toward or away from one another. This feature is of importance when unrolling portions of carpet from bulk rolls of various width carpet, thereby adding significant versatility to the present apparatus.  
         [0036]     Also removably mounted on the top surface of the first dolly is a third upright standard  210  which serves to removably mount a first probe  212  which extends in cantilevered fashion from the upper end  214  of the standard in a direction along the length of the present apparatus. The distal end of the probe is tapered, i.e., generally conical in geometry, so as to be readily insertable into the center of a bulk roll of carpet for loading a bulk roll of carpet onto the present apparatus and support of such bulk roll while allowing for the rotation of the bulk roll about the probe in the course of unrolling portions of the carpet from the bulk roll. Further support for the bulk roll is provided at its opposite end as by a second probe  218  which is removably mounted in a fourth upright standard  220  which is itself removably mounted on the top surface  204  of the second dolly  192 . In one example, the first probe is about nine feet in cantilevered length and the second probe is about three feet in cantilevered length. Like the first probe, the distal end  222  of the second probe is tapered to enhance the entry of this second probe into the center of the bulk roll of carpet.  
         [0037]     It will be noted that the first and second dollies are moveable along their respective rails toward and away from one another to select their effective combined overall length. Also, as noted, the first and second tubes are slidably associated at their ends, hence their combined overall length is also selectable as a function of the relative movements of the first and second dollies. Thus, provision is made within the present invention for the mounting and manipulation of bulk rolls of carpet of different widths.  
         [0038]     As needed or desired, a third dolly  224  is rollably mounted on the inverted “v” rails on the top surface of the first and second rails of the third rail set at a location intermediate the first and second dollies. This third dolly is provided with a planar platform  226 . In this dolly, there is mounted centrally of the platform a support member  228  which is vertically adjusted by means of a bottle jack  230  disposed underneath and extending upward through a central opening  232  through the platform. This bottle jack provides for lifting and lowering of the support member as needed to provide support for a bulk roll of carpet intermediate its opposite ends. In one embodiment, this support member is curved upwardly away from the horizontal at its opposite side portions  234 , 236  to assist in reduction of lateral bending of a bulk roll of carpet as the bulk roll is being manipulated and/or unrolled in the course of disbursement of portions thereof. Being rollably mounted on the rails of the third rail set, the third dolly may be positioned at substantially any location between the first and second dollies as desired. For example, the third dolly may be initially positioned near the distal end of the first probe as a bulk roll of carpet is fed onto the first probe and then move with the carpet as the carpet is further inserted onto the first probe. Through adjustment of the vertical position of the support member of the third dolly, the support provided by such support member may be selected as needed for a given bulk roll of carpet. In one sense, because the third dolly is movable independent of the movement of the first and/or second dollies, the third dolly may be “self-seeking” with respect to the support offered to a bulk roll of carpet. Further, in one embodiment, one upwardly side portion  234  of the support member may be extended to lie beneath a portion of carpet being collected on the first and second tubes  186 , 190  which extend between the first and second dollies.  
         [0039]     As noted each of the dollies of the present invention, and/or those components supported on the dollies are removable, thereby providing for “break-down” of the apparatus for any of several reasons, such as storage, ease of manual assembly and/or manipulation of the components, etc. It will be recognized, therefore, that various removable pins, safety and otherwise, may be employed in a conventional manner to hold the removable components in place during use of the apparatus and for releasing such components as desired.  
         [0040]     In one embodiment of the method of the present invention, the first rail set is anchored in a vehicle with the second and third rail sets are telescopically mounted on the first rail set. Various of the components of the apparatus are removed from the rail sets, including the dollies, as needed, for ease of temporary transport or storage of the apparatus. In preparation for the loading of a bulk roll of carpet onto the apparatus, the second rail set (carrying the third rail set therewith) is extended, aligned and stabilized. Next, the third rail set is moved toward its extended attitude, accompanied by careful adjustment of the relative vertical planes and length alignments of the second third rail sets with respect to the vertical plane and length dimension of the first rail set, through the application and manipulation of the jacks and their respective height selections. Once the rail sets are extended, aligned and stabilized, the dollies and their accompanying components are mounted onto their respective supporting rails. Thereupon, commonly using a forklift or like mechanical lifting apparatus, a bulk roll of carpet is loaded onto the first probe, followed by insertion of the second probe on the distal end of the bulk roll of carpet, thereby providing support for both ends of the bulk roll of carpet. As needed or desired, the third dolly is positioned under the bulk roll of carpet in supporting position of the central portion of the bulk roll of carpet intermediate the first and second dollies.  
         [0041]     Once a bulk roll of carpet has been fully loaded onto the probes, the loose end of the roll of carpet is manually drawn over and about the first and second collection tubes. Employing the number of turns of the wheel which drives the first and second tubes, a desired length of carpet is unrolled from the bulk roll and collected on the collection tubes. This portion of carpet is then severed from the roll. Once severed, the collected portion of the carpet is removed from the apparatus by pulling horizontally on the wheel to withdraw the first and second tubes from the interior of the collected rolled portion of the carpet and carried manually to its place of installation.