Abstract:
A carpet stretching apparatus is provided. The apparatus can comprise a rail having a fixed pin block operatively disposed at one end thereof, with the pin block configured with a plurality of pins configured to engage the backing of the carpet thereby enabling the pin block to grip or otherwise releasably attach to the carpet. The apparatus can further comprise a travelling mechanism disposed on the rail, the mechanism further comprising a second pin block disposed thereon that can work in cooperation with the fixed pin block. When the travelling mechanism is operated, the pin blocks work in cooperation to stretch or move the carpet.

Description:
PRIORITY STATEMENT &amp; CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part application of U.S. patent application Ser. No. 12/350,670 filed Jan. 8, 2009, which claims priority of U.S. Provisional Patent Application Ser. No. 61/021,179 filed Jan. 15, 2008 and hereby incorporates these documents by reference herein in their entirety. This application also claims priority of U.S. Provisional Patent Application Ser. No. 61/245,738 filed Sep. 25, 2009 and hereby incorporates the same provisional application by reference herein in its entirety. 
     
    
     TECHNICAL FIELD OF THE INVENTION 
       [0002]    The present disclosure is related to the field of carpet stretching apparatuses, in particular, hand-operated tools for use in stretching carpet to aid in its installation. 
       BACKGROUND OF THE INVENTION 
       [0003]    It is known to use hand-operated tools to stretch carpet to aid in its installation. Such tools are cumbersome and often require considerable physical strength on the part of the installer. Different carpet stretching tools are often required depending on the type of carpet being installed and where it is installed. 
         [0004]    It is, therefore, desirable to provide an apparatus for stretching carpet that is easy to operate and includes accessories that allow a single apparatus to be used in installing in various configurations and applications. 
       SUMMARY OF THE INVENTION 
       [0005]    An apparatus for stretching carpet is provided in the description herein. In some embodiments, the apparatus can comprise a rail having a fixed pin block operatively disposed at one end thereof, the pin block configured with a plurality of pins further configured to engage the backing of the carpet thereby enabling the pin block to grip or otherwise releasably attach to the carpet. In some embodiments, the pin block can comprise the pin block as described and shown in U.S. Pat. No. 7,237,764 issued on Jul. 3, 2007, said patent incorporated into this application by reference in its entirety. 
         [0006]    In some embodiments, the pin block can comprise a parallelepiped baseblock that can further comprise a plurality of pins extending downwardly from the bottom surface of the baseblock. The pins can be linearly aligned in a single file along the bottom surface of the baseblock. Each pin extending from the baseblock can be encased in a cylindrical pin support such that only the pin tip is exposed and protruding downward from the end surface of the pin support, which can be adapted for contacting a carpet backing. In some embodiments, each baseblock can comprise between two to eight pin supports. In other embodiments, each baseblock can comprise between four to six pin supports. In a representative embodiment, the baseblock can comprise five pin supports. 
         [0007]    In some embodiments, each pin support can be canted towards the front surface of the baseblock as it extends downward. In further embodiments, the pin supports can be canted at an angle of approximately 75° to approximately 45° with respect to the bottom surface. In a representative embodiment, this angle can be approximately 60°. 
         [0008]    In some embodiments, a fin can extend between each adjacent pair of pin supports that intersects with the bottom surface. The pin block can further comprise a strengthening gusset extending between the bottom surface and the pin support closest to the front surface. Each fin can comprise a downward edge that is flush with the end surface of the pin supports whereby the combination of the end surfaces and the downward edges of the fins can form a single continuous contact surface that is substantially parallel to the bottom surface. 
         [0009]    In some embodiments, the combination of the fins and the pins supports can extend approximately ⅜″ to approximately ⅝″ downward from the bottom surface of the baseblock. Each pin tip can extend approximately ⅛″ from the end surface of its pin support. 
         [0010]    In some embodiments, each baseblock can comprise a protrusion extending from one side surface and a recess on the other side surface whereby the protrusion of one pin block can releasably interlock with the recess of another pin block. Therefore, a number of pin blocks can be releasably interlocked and aligned together to form a ganged pin block for a carpet gripping device, the ganged pin block having superior gripping power over a single pin block. 
         [0011]    In operation, a number of pin blocks can be stacked together side by side to form a ganged gripping block installed in a carpet gripping device. The ganged block can be placed on the carpet with each pin tip piercing the carpet backing but the depth of penetration limited by the length of the pin tip and the contact surface formed by the fins and the end surfaces. The depth of the fins and pin supports can be set to accommodate the typical height of the fibers of the carpet. The length of the pin tip can be selected to penetrate the carpet backing but not to extend through the carpet backing and perforate any membrane on the bottom layer of the carpet backing or to tear the underlay as the carpet is stretched into position. 
         [0012]    In some embodiments, the apparatus can further comprise a travelling mechanism disposed on the rail, the mechanism further comprising a second pin block disposed thereon that can work in cooperation with the fixed pin block. The mechanism can be configured to travel in a one-way direction on the rail when a lever disposed on the mechanism is operated. 
         [0013]    In some embodiments, the apparatus can be further configured so that the travelling mechanism can move away from the fixed pin block with the fixed and second pin blocks configured with the pins facing away from each other whereby carpet can be stretched between the two pin blocks. The apparatus can also be further configured so that the travelling mechanism can move towards the fixed pin block with the fixed and second pin blocks configured with the pins facing towards each other whereby two pieces of carpet can be stretched towards each together to be seamed together using a carpet seaming tool. 
         [0014]    In some embodiments, the apparatus can comprise one at least one support rod disposed on the apparatus to guide the movement of the travelling mechanism. In some embodiments, the apparatus can comprise a housing to enclose the travelling mechanism. In further embodiments, the housing can comprise at least one passageway through which the at least one support can pass through to guide the movement of the travelling mechanism. In some embodiments, the housing can further comprise means for releasably attaching to an extension tube that can further comprise a third pin block. The extension tube can be of varying lengths, depending on the application the apparatus is being used for. With a short extension tube installed, the apparatus can be used for stretching and installing carpet on stairs. With a long extension tube installed, the third pin block can comprise a backstop wherein the apparatus can be configured as a deadman stretcher for stretching wider expanses of carpet. 
         [0015]    Broadly stated, in some embodiments, an apparatus is provided, comprising: a longitudinal rail having first and second ends; a first bracket disposed on the first end, and a second bracket disposed on the second end; a first pin block foot disposed on the first bracket, the first pin block configured to grip a first patch of carpet; a travelling module operatively disposed on the rail, the travelling module further comprising means for moving the travelling module along the rail; and a second pin block foot disposed on the travelling module, the second pin block configured to grip a second patch of carpet wherein operating the moving means causes the second pin block foot to move the second patch of carpet relative to the first patch of carpet. 
         [0016]    Broadly stated, in some embodiments, a carpet installation tool is provided, comprising: a longitudinal rail having first and second ends; a first bracket disposed on the first end, and a second bracket disposed on the second end; a first pin block foot disposed on the first bracket, the first pin block configured to grip a first patch of carpet; a travelling module operatively disposed on the rail, the travelling module further comprising means for moving the travelling module along the rail; and a second pin block foot disposed on the travelling module, the second pin block configured to grip a second patch of carpet wherein operating the moving means causes the second pin block foot to move the second patch of carpet relative to the first patch of carpet. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0017]      FIG. 1  is a perspective view depicting a first embodiment of a carpet stretching apparatus; 
           [0018]      FIG. 2  is an upper perspective view depicting the carpet stretching apparatus of  FIG. 1 ; 
           [0019]      FIG. 3  is a side elevation view depicting the carpet stretching apparatus of  FIG. 1 ; 
           [0020]      FIG. 4  is a side elevation view depicting the carpet stretching apparatus of  FIG. 3  as it is being operated; 
           [0021]      FIG. 5  is a perspective view depicting an alternate embodiment of the operating mechanism of a carpet stretching apparatus; 
           [0022]      FIG. 6A  is a side elevation view depicting the operating mechanism of the depicting the carpet stretching apparatus of  FIG. 1 ; 
           [0023]      FIG. 6B  is a side elevation view depicting the operating mechanism of  FIG. 6A  as it is being operated; 
           [0024]      FIG. 6C  is a side elevation view depicting the operating mechanism of  FIG. 6A  as it is being released; 
           [0025]      FIG. 7A  is a side elevation view depicting the operating mechanism of the depicting the carpet stretching apparatus of  FIG. 5 ; 
           [0026]      FIG. 7B  is a side elevation view depicting the operating mechanism of  FIG. 7A  as it is being operated; 
           [0027]      FIG. 7C  is a side elevation view depicting the operating mechanism of  FIG. 7A  as it is being released; 
           [0028]      FIG. 8A  is a perspective view depicting the carpet stretching apparatus of  FIG. 1  with a stretcher tube; 
           [0029]      FIG. 8B  is a perspective view depicting the carpet stretching apparatus of  FIG. 5  with a stretcher tube; 
           [0030]      FIG. 9A  is a perspective view depicting the carpet stretching apparatus of  FIG. 1  with a tail blade; 
           [0031]      FIG. 9B  is a perspective view depicting the carpet stretching apparatus of  FIG. 5  with a tail blade; 
           [0032]      FIG. 10  is a side elevation view depicting the carpet stretching apparatus of  FIG. 9B ; 
           [0033]      FIG. 11  is a side elevation view depicting an alternate embodiment of the carpet stretching apparatus of  FIG. 9A ; 
           [0034]      FIG. 12  is a side elevation view depicting the carpet stretching apparatus of  FIG. 1  with extended legs; 
           [0035]      FIG. 13  is a perspective view depicting the carpet stretching apparatus of  FIG. 5  configured for stretching carpet on stairs; 
           [0036]      FIG. 14  is a perspective view depicting the carpet stretching apparatus of  FIG. 1  configured for stretching carpet on stairs; 
           [0037]      FIG. 15  is a perspective view depicting the carpet stretching apparatus of  FIG. 5  configured as a deadman stretcher with a backstop for stretching wider expanses of carpet; 
           [0038]      FIG. 16  is a perspective view depicting the backstop of the carpet stretching apparatus of  FIG. 15 ; 
           [0039]      FIG. 17  is a top plan view depicting the backstop of  FIG. 16 ; 
           [0040]      FIG. 18  is a top plan view depicting the backstop of  FIG. 16  in an angled position; 
           [0041]      FIG. 19  is a side elevation view depicting a top plan view depicting the backstop of  FIG. 16 ; 
           [0042]      FIG. 20  is a perspective exploded view depicting the backstop of  FIG. 16 ; and 
           [0043]      FIG. 21  is a perspective exploded view depicting the backstop of  FIG. 16 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0044]    Referring to  FIGS. 1 through 4 , an embodiment of a carpet stretching apparatus, denoted as apparatus  10 , is illustrated. Apparatus  10  can comprise travelling module  12  slidably disposed on rail  14  whereby module  12  can move linearly along rail  14 . In some embodiments, module  12  can comprise a travelling mechanism as shown in PCT Publication No. WO 2005/056240, published 23 Jun. 2005, and in United States Publication No. 2008/053262, published 6 Mar. 2008, both of which documents are incorporated by reference into this application in their entirety. Disposed at one end of rail  14  can be bracket  20 . On the other end of rail  14 , there can be disposed bracket  22 . Pin block holders  26  can be disposed on the bottom side of bracket  20  and module  12 , respectively. Pin block holders  26  can be configured to receive at least one pin block  28 . In a further embodiment, pin block holders  26  can be configured to each hold one or more pin blocks  28  stacked side to side to form a ganged pin block. In yet a further embodiment, pin block  28  can comprise the pin blocks as described and claimed in U.S. Pat. No. 7,237,764. In another embodiment, apparatus  10  can further comprise one or more support rods  24  disposed between brackets  20  and  22 . The addition of support rods  24  can provide additional rigidity to apparatus  10  to prevent rail  14  from bowing when apparatus  10  is in use. Referring to  FIG. 4 , when force F is applied downwardly to handle  16 , handle  16  can pivot about handle pivot  30  to apply force to pin  34  disposed on module  12 . In so doing, module  12  can advance along direction D on rail  14  as shown in  FIG. 4 . When force F is released from handle  16 , handle  16  can return to an upright position and module  12  is then fixed in a stationary position on rail  14 . When force is applied to release handle  18  pivotally attached to module  12  at release pivot  32 , module  12  can be released from its position on rail  14  and can be manually moved in either direction along rail  14 . It is obvious to those skilled in the art that apparatus  10  can be configured such that module  12  can advance in a direction opposite to direction D on rail  14  when force F is applied to handle  16 . 
         [0045]    Referring to  FIG. 5 , an alternate embodiment of apparatus  10  is shown. In some embodiments, support rods  24  can be substantially aligned with rail  14  in a horizontal plane. In some embodiments, pin  25  can be used to stabilize support rods  24  with respect to rail  14  by passing through rods  24  and rail  14  near each of brackets  20  and  22 . In some embodiments, module  12  can comprise grooves  13  on its sidewalls to partially receive support rods  24  as a means for guiding module  12  as it travels along rail  14 . In some embodiments, the application of downward force F on lever  16  causes module  12  to move along direction D as shown in  FIG. 5 . 
         [0046]    Referring to  FIGS. 6A ,  6 B and  6 C, one embodiment of operating mechanism  36  disposed in module  12  is shown. Operating mechanism  36  is a device that can provide one-way linear travel along rail  14 . When force F is applied to handle  16 , thereby imparting force on pin  34  disposed on mechanism  36 , module  12  can advance along rail  14  along direction D. Mechanism  36  and rail  14  can be of any suitable equivalent mechanism or rail as well known to those skilled in the art. In some embodiments, rail  14  and mechanism  36  can comprise the rail and travelling mechanism as used in Irwin model XP600 “Quik Grip™” bar clamp/spreaders, as manufactured by Irwin Industrial Tool Company, A Division of Newell Rubbermade, Inc. of 10 B Glenlake Parkway, Atlanta, Ga., U.S.A. When release force R is applied to release handle  18 , module  12  can be released from rail  14  and then be manually moved along rail  14  in either direction. 
         [0047]    Referring to  FIGS. 7A ,  7 B and  7 C, another embodiment of operating mechanism  36  disposed in module  12  is shown. In some embodiments, operating mechanism  36  can be disposed in housing  35 . Housing  35  can further comprise passageways  33  disposed therethrough to permit support rods  24  to pass therethrough to guide module  12  as it moves along rail  14 . In some embodiments, housing  35  can further comprise tube receiver neck  37  as attachment means for receiving or releasably attaching an extension tube that can be inserted in neck  37 . In further embodiments, neck  37  can comprise aperture  39  for receiving a spring-loaded locking pin disposed on the extension tube to releasably connect the extension tube to housing  35 . When force F is applied to handle  16 , module  12  can advance along rail  14  along direction D. When release force R is applied to release handle  18 , module  12  can be released from rail  14  and then be manually moved along rail  14  in either direction. 
         [0048]    Referring to  FIG. 8A , an embodiment of apparatus  10  showing a complement of other attachments is shown. In some embodiments, apparatus  10  can further comprise a stretcher tube  40  having backstop  38  mounted at an end thereof. The use of stretcher tube  40  and backstop  38  enables apparatus  10  to stretch a broader expanse of carpet. Apparatus  10  can further comprise bracket  50  having pin block holder  26  attached thereto further comprising at least one pin block  28 . Bracket  50  can further comprise tail blade holder  46  having tail blade  48  attached thereon. The use of tail blade  48  enables apparatus  10  to work with a tack strip mounted on a floor when installing carpet thereon, as well known to those skilled in the art. 
         [0049]    Referring to  FIG. 8B , another embodiment of apparatus  10  showing a complement of other attachments is shown. In some embodiments, apparatus  10  can further comprise a stretcher tube  40  having backstop  38  mounted at an end thereof. The use of stretcher tube  40  and backstop  38  enables apparatus  10  to stretch a broader expanse of carpet. Apparatus  10  can further comprise bracket  50  having pin block holder  26  attached thereto further comprising at least one pin block  28 . Bracket  50  can further comprise tail blade holder  46  having tail blade  48  attached thereon. The use of tail blade  48  enables apparatus  10  to work with a tack strip mounted on a floor when installing carpet thereon, as well known to those skilled in the art. 
         [0050]    Referring to  FIGS. 9A ,  9 B and  10 , other embodiments of apparatus  10  are shown for use with tack strip  58  installed on floor  60 .  FIG. 9A  shows one embodiment of apparatus  10 .  FIG. 9B  shows another embodiment of apparatus  10 . Bracket  50  can further comprise tail blade  48  attached directly to bracket  50  by having threaded knob  52  pass through an opening (not shown) disposed on tail blade  48 , and into bracket  50 . Tension knob  52  can be tightened to secure tail blade  48  to bracket  50 . This arrangement can also allow tail blade  48  to pivot on tension knob  52 , which can allow apparatus  10  to stretch carpet at an angle with respect to tack strip  58 , which can be grasped by tail blade  48 . 
         [0051]    Referring to  FIG. 11 , an alternate embodiment of apparatus  10  as shown in  FIGS. 9 and 10  is illustrated. In some embodiments, apparatus  10  can further comprise spacer  54  disposed between bracket  50  and tail blade  48 , and spacer  56  disposed between module  12  and pin block holder  26 . This embodiment enables apparatus  10  to be elevated above the floor so as to allow a carpet seaming tool (not shown) to pass under rail  14  between spacers  54  and  56 . 
         [0052]    Referring to  FIG. 12 , another embodiment of apparatus is shown. In some embodiments, apparatus  10  can further comprise bracket  50  disposed on one end of rail  14  having spacer  64  disposed between bracket  50  and pin block holder  26 . Module  12  can further comprise spacer  62  disposed between module  12  and another pin block holder  26 . This embodiment of apparatus  10  enables a carpet seaming tool (not shown) to pass under rail  14  between spacers  62  and  64 . Apparatus  10  is used in this configuration to bring adjoining pieces of carpet together so that they can be seamed in a continuous fashion. 
         [0053]    Referring to  FIG. 13 , another embodiment of apparatus  10  is shown. In some embodiments, apparatus  10  can be used for stretching carpet on stair treads. In this configuration, apparatus  10  can comprise adaptor  66  disposed between bracket  20  and pin block holder  26 . Module  12  can further comprise extension tube  68  inserted into neck  37 . Tube  68  can be held in place in neck  37  by spring-loaded locking pin  69  passing through pin aperture  39 . To remove extension tube  68  from housing  35 , pin  69  can be depressed such that it clears aperture  39  thereby allowing tube  68  to be removed from neck  37 . Extension tube  68  can comprise adaptor  70  attached to the far end thereof and further comprise another pin block holder  26  disposed on the bottom thereof. In this configuration, when handle  16  is operated, pin block holders  26  can move away from each other thereby stretching the carpet therebetween for proper installation on a stair tread. 
         [0054]    Referring to  FIG. 14 , another embodiment of apparatus  10  is shown. In some embodiments, apparatus  10  can be used for stretching carpets on a stair tread from the front of the step to the rise of the following step. In some embodiments, bracket  22  can further comprise support stand  72 , which can allow apparatus  10  to be supported by a lower stair tread while stretching carpet on the stair tread from front to rear. 
         [0055]    Referring to  FIG. 15 , another embodiment of apparatus is shown. In some embodiments, apparatus  10  can comprise extension tube  40  operatively attached to module  12  at one end, and that further comprises backstop  38  at the other end thereof. Apparatus  10  can be further configured to allow extension tube  40  to releasably connect with module  12 . In the illustrated embodiment, backstop  38  will move away from pin block holder  26 , operatively attached to adaptor  66  and bracket  20 , when handle  16  is operated. 
         [0056]    Referring to  FIGS. 16 through 21 , an embodiment of backstop  38  is shown. In some embodiments, backstop  38  can be configured with a central backstop unit  74  and with modular extension units  76  operatively attached on either end thereof. Central unit  74  can be pivotally attached to clevis joint  78  having channel lock  80  that can be configured to releasably attach to extension tube  40 . In a further embodiment, tension knob  82  can pass through an opening disposed in clevis  78  and clevis receiver  86  into a central clevis receiver  86 . Clevis receiver  86  can be operatively attached to central unit  74  using fasteners as well known to those skilled in the art. These can include but are not limited to screws, bolts, socket head screws, thumb screws, threaded knobs, bayonet connectors, or any other functionally equivalent fasteners. In another embodiment, clevis receiver  86  can be configured to allow backstop  38  to be tilted to the left or to the right with respect to extension tube  40 , as shown in  FIG. 18 . 
         [0057]    Referring to  FIG. 19 , a side elevation view of one embodiment of backstop  38  is shown. In some embodiments, pin block  28  can be disposed in backstop  38  at an angle  84 . Configuring backstop  38  with an angle pin block  28  allows backstop  38  to “bite-in” into a carpet when apparatus  10  is being operated to stretch the carpet. The operation of apparatus  10 , when stretching carpet, will have the effect of bowing extension tube  40  upwards. In so doing, backstop  38  can rotate downwards thereby reducing angle  84  whereupon pin block  28  can “bite-in” into the carpet even further. 
         [0058]    Referring to  FIG. 21 , an exploded view of extension unit  76  of backstop  38  is shown. Extension unit  76  can comprise pin block holder  92 , which can abut central unit  74 . Bracket plate  94  can then be inserted in grooves disposed on top of pin block holder  92  and into corresponding grooves on the top of central unit  74 . Threaded fasteners  90  can then be used to pass through openings disposed on top of bracket plate  94  into corresponding threaded holes in central unit  74  and pin block holder  92  to hold the elements together. In yet a further embodiment, end bracket  96  can be also installed on the end of pin block holder  92  underneath bracket plate  94  and held in place by a fastener  90 . In some embodiments, fasteners  90  can comprise screws, bolts, socket head screws, thumb screws, threaded knobs, bayonet connectors, or any other functionally equivalent fasteners as well known to those skilled in the art. 
         [0059]    Although a few embodiments have been shown and described, it will be appreciated by those skilled in the art that various changes and modifications might be made without departing from the scope of the invention. The terms and expressions used in the preceding specification have been used herein as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding equivalents of the features shown and described or portions thereof, it being recognized that the invention is defined and limited only by the claims that follow.