Abstract:
A plank top set tool for driving hardwood staples including a body having an underside base surface which contacts a base top and an angled stop surface fitting over the vertical surface leading to the tongue base. Extending at a 45 degree angle through the block is a staple slot bore having a staple slot width. A rod is insertable into the bore and has a first end acting as a hammering head to receive an impact force and a second end configured to receive a staple head and transfer the force.

Description:
TECHNICAL FIELD  
       [0001]    The present invention relates to flooring tools and more specifically to tools for setting hardwood plank staples. 
       BACKGROUND  
       [0002]    In the installation of tongue and groove hardwood plank flooring materials, pneumatic staplers are commonly used to drive staples used to adhere the planks to the floor. These staplers are designed to sit flat on top of the hardwood plank and locate against a tongued side of the plank such that they can precisely drive the staple at a 45° angle at a point just above the tongue. The driving angle of 45° and driving elevation at the point just above the tongue are fixed and standard for most modern pneumatic hardwood staplers. The standard angle and point of entry for driving staples works well because the hardwood planks themselves normally have standard tongue and groove dimensions. 
         [0003]      FIG. 8  shows the shape of a typical modern hardwood staple  50 . As used herein, a typical hardwood staple  50  has dimensions defined as follows: dimension  51  is the length of the hardwood staple (sometimes also referred to as a “leg”), dimension  52  is the width of the hardwood staple (sometimes also referred to as a “crown”), and dimension  53  is the thickness of the hardwood staple. Modern hardwood staples are typically wire form products made from round wire. Hence the crown  52  of this kind of staple tends to form a longitudinally rounded surface  54 . In comparison to other staples, modern hardwood flooring staples have long, brittle legs that will easily break if they are not supported during the driving process. 
         [0004]      FIG. 5  illustrates by way of a cross sectional view the proper stapling of a tongue and groove hardwood plank. A first plank  11  has a hardwood staple  12  driven fully at a 45° angle into the vertex  13  of the exterior angle formed by an outer edge  14  and a tongue  15  of first plank  11 . Hardwood staple  12  anchors first plank  11  to subfloor  16 . Provided hardwood staple  12  is fully driven into the vertex  13  of first plank  11 , the tongue  15  of plank  11  fits easily into groove  18  of second plank  17 , and the stapling process continues by stapling at same area of the next plank (vertex  19  of second plank  17 ). 
         [0005]    As shown in  FIG. 10 , the exterior angle formed by tongue outer edge  74  on the tongued side of the plank and a tongue  75  of a typical hardwood plank  71  may not be a 90° angle. The angle D formed between tongue outer edge  74  and tongue  75  is normally about 89.5°. Similarly, groove outer edge  70  on the opposite groove side of the plank is at an angle E of about 88.5° in relation to a centerline  71  of the plank  11 . As shown in  FIG. 11 , these angles relieve tongue outer edge  74  and groove outer edge  70  from each other when butted together. This ensures tongue outer edge  74  and groove outer edge  70  will only contact near tongue top edge  72 , and groove top edge  73 . This ensures that there will be minimal interference between the edges which could create a gap at the top of the joint. 
         [0006]    In the use of pneumatic hardwood staplers, knots in the hardwood plank or drops in air pressure may cause the nailer to only partially drive the staple, leaving an undesirable exposed staple head.  FIG. 6  illustrates the problem. Hardwood staple  10  has been partially driven into the side of the hardwood plank, leaving an exposed staple head  2 . Whenever there is an exposed staple head, the tongue of a first plank and the groove of the next plank will not fit together. The floor installation process comes to a halt. 
         [0007]    Presently, hardwood installers normally carry snips and conventional nail sets to hammer down partially driven staples. The staple legs have to be separated from the crown, and then the legs can be driven using a conventional nail set. This is a difficult, time consuming process. If a set tool were available to drive the entire exposed staple head the rest of the way into the side of the plank, it would greatly speed the process of installation. The process of driving a partially driven staple or exposed staple head will be referred to herein as a process of “finish hammering” the hardwood staple. 
         [0008]    Tools have been developed for hammering nails into the side of tongue and grooved flooring materials, but none for finish hammering modern hardwood staples from pneumatic staplers. For example, U.S. Pat. No. 1,016,383 to Wellman discloses a set tool with a plate which sits flat on the hardwood plank. The plate includes a “V-rib” or 90° internal angle surface formed in its base. The V-rib is shaped to conform to the plank at the exterior angle formed by the outer edge of the plank and the tongue of the plank (also referred to as a “rabbet” as this term is used in woodworking). Thus, the V-rib functions to position the plate at a precise location “to permit the effective drive of nails”. A circular “passage” for inserting a round headed nail is formed at a 45° degree angle through the plate to the vertex of the V-rib. Thus, when the point of the nail is inserted into the passage, it is automatically located at the optimal location for driving the nail at a 45° angle into the side of the plank. 
         [0009]    In addition, the disclosed device includes a “punch or driving element” for use in connection with the plate. The punch is a generally cylindrical rod with a reduced outside diameter on one end which can slidably fit within the passage in the plate. This reduced diameter end can slide within the passage all the way to the bottom of the passage, and can thus drive the nail all the way down to the bottom of the passage. Thus, as this disclosure states, “the nail can be entirely driven into the flooring without removing the improved implement” (i.e., the “plate”). 
         [0010]    Wellman&#39;s floor set may have worked well for the purpose of driving nails, but it is not suitable for the purpose of finish-hammering partially driven modern hardwood staples. The reason is that the passages are merely cylindrical holes designed for the passage of round headed nails. In comparison, modern hardwood staples are fairly thin, U-shaped metal wire form products. Effectively driving such staples requires that the staple be precisely supported all the way into the material by means of a precision staple channel that is shaped to create a precision slide fit with the dimensions of the staple. If a user attempted to drive such a staple with only a hammer, the lack of support means would cause the thin metal legs of the staple to bend over or break. The passage of the Wellman device will not provide the necessary precision support means for supporting the staple. 
         [0011]    Other prior art set tools have been developed for driving staples, but they all have drawbacks. U.S. Pat. No. 1,213,334 to Chapman discloses a single-piece driving rod type staple set with a plurality of “sockets” (i.e., “blind-hole” staple channels) of varying depths formed in its driving head. The reference states that “the sockets are made of gradually decreasing depths so as to accommodate the staple at various stages of its entrance into the wood in which it is being set.” Thus, the user begins by inserting a staple in the deepest channel, and hammers on the opposite end to start the driving process. Once the driving head contacts the wood, the user inserts the staple head into one of the shallower sockets, and the staple can be driven further. The legs of the staple are supported by the various sockets, preventing them from spreading or bending over. This device is not suitable for the purpose of finish hammering hardwood staples because the plurality of sockets requires a wide head. Such a wide head does not easily enter the exterior angle formed by the outer edge of the plank and the tongue of the plank. Furthermore, modern hardwood staples are by comparison much longer and thinner than the staples shown by Chapman. More sockets of even greater depth would be necessary, and the sockets would need to be thinner. Forming enough thin blind sockets into the head would become impractical. Finally, there is no means to maintain the prescribed 45° angle during the finish hammering process. What is needed is a tool with a single staple slot with a length at least as long as the hardwood staple, and a means of driving the head of the hardwood staple down the length of the staple channel. The staple channel could be formed at the prescribed 45° angle. 
         [0012]    Other similar set tools, such as that disclosed in U.S. Pat. No. #D493079 S to Fowler, have more compact, relieved driving heads which include a single staple socket. Such a compact driving head can more easily enter the exterior angle formed by the outer edge of the plank, and the tongue of the plank. However, there is no means of support for the legs of the staple. This type of tool is not helpful in cases where the staple protrudes a significant distance from the hardwood plank. Without support during the driving process, the staple simply bends over. 
         [0013]    What is needed is a set tool for finish hammering modern hardwood staples which properly supports the legs of these staples throughout the process of finish hammering while also maintaining the prescribed 45° angle and location on the plank where such staples are normally driven. 
       SUMMARY  
       [0014]    The device is a set tool including a block-like body with a staple slot formed within said body, and a separate driving rod to drive the staple. The body may sit on the face of the hardwood plank on a body base surface. The body further includes a downwardly extending arm. On its inside surface, the arm forms a stop surface for the set tool. The external angle formed by the body base surface and the stop surface is preferred to be about 75°. This angle relieves the stop surface from the outside edge of the plank (approximately 89.5° external angle in relation to the tongue), and prevents impact of the set tool at the top edge of the plank (which can cause chipping). The stop surface extends to a location where it forms a staple insertion edge with an arm base surface. The extension of the stop surface places the staple insertion edge at the vertex of the external angle formed by the outer edge of the hardwood plank, and the tongue of the plank. The arm base surface is parallel to the body base surface, and rests on top of the tongue of the plank. A staple slot is formed at the prescribed 45° angle within the body, and ending at the staple insertion edge. In use, the partially driven hardwood staple is inserted in the staple slot. The body base surface is then set on the hardwood plank. The extension and angle of the stop surface places the staple insertion edge at the vertex of the external angle formed by the outer edge of the plank, and the tongue of the plank. The user inserts the rod in the staple slot. The user slides the rod in the staple slot until it contacts the head of the staple. The user hammers the rod with a hammering tool, and the staple is driven into the hardwood plank at the prescribed angle and location. Support from the precision staple slot ensures the staple will not bend over during the process of finish hammering. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS  
         [0015]      FIG. 1  is a disassembled perspective view of the set tool showing the body and the driving rod. 
           [0016]      FIG. 2  is a bottom perspective view of the set tool body. 
           [0017]      FIG. 3  is a detailed side view of the rod. 
           [0018]      FIG. 4  is an assembled view of the set tool. 
           [0019]      FIG. 5  is a cross-sectional view of a hardwood plank showing a properly driven hardwood staple. 
           [0020]      FIG. 6  is a cross-sectional view of an exposed staple head in a hardwood plank. 
           [0021]      FIG. 7  is a vertical cross section of the set tool bisecting the 45° angle hole to show the insertion of an exposed staple head. 
           [0022]      FIG. 8  is a perspective view of a typical hardwood staple. 
           [0023]      FIG. 9  is a perspective view of an alternative rod for the set tool having a thin metal tip. 
           [0024]      FIG. 10  is a cross section of a hardwood plank showing the angles formed by the outer edge of the plank on both the tongued side and the grooved side of the plank. 
           [0025]      FIG. 11  is a cross section of two hardwood planks showing how the angles formed by the relieved outer edges on both the tongue and grooved sides the plank interact to prevent a gap from forming between the planks. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0026]    As shown in  FIG. 1 , set tool  100  includes a block-like body  200  and a rod  300 . Body  200  includes a flat body base surface  205  for setting body  200  flat on the face of a hardwood plank, and an arm  210  extending downward to form a stop surface  215 . As shown in  FIG. 2 , a bottom view of body  200 , stop surface  215  forms an external angle B in relation to body base surface  205 . Angle B could be any angle in the area of 90° corresponding roughly to the shape of the external angle formed by outside edge of the hardwood plank, and the tongue of the plank (approximately 89.5°). However, it is preferred that this angle B be about 75°. As shown in  FIG. 7 , such an angle causes stop surface  215  to be slightly relieved from outer edge  14  and top edge  22  of a plank. This ensures that when the outer edge of the hardwood plank is placed up next to stop surface  215 , stop surface  215  will not contact the top edge  22  of the plank  11 . This prevents the top edge of the hardwood plank from being chipped by impacts from the body. 
         [0027]    As shown in  FIG. 1 , arm base surface  225  intersects stop surface  215  to form a staple insertion edge  220 . Arm base surface  225  is parallel to body base surface  205 . As shown in  FIG. 7 , the angled extension of stop surface  215  places a staple insertion edge  220  precisely at the vertex of the external angle formed by the outer edge  14  of the plank, and the tongue  15  of the plank. This is precisely the point in the plank from which that an exposed staple head normally extends. 
         [0028]    As shown in  FIG. 1 , a 45° hole  230  is formed extending from top surface  235  in body  200  through to staple insertion edge  220 . As used herein, the measurement of angle of 45° used to describe 45° hole  230  is illustrated in  FIG. 7 . The angle A formed by the plane formed by body base surface  205  and a centerline  275  of 45° hole  230  is about 45°. 
         [0029]    As shown in  FIG. 1 , 45° hole  230  is a round hole. 45° hole  230  has a center  240 . Center  240  forms one end of a centerline of 45° hole  230  that extends downward at an angle of 45° and ends precisely at staple insertion edge  220 . Thus, when viewed from center  240 , 45° angle hole  230  is bisected by a 45° plane extending upwards from the line formed by staple insertion edge  220  to center  240 . Also in this plane is a “bisecting diameter”  245  of 45° hole  230 . The plane between staple insertion edge  220  through bisecting diameter  245  (and through center  240 ) will be referred to herein as the “45° bisecting plane” of hole  230 . 
         [0030]    The shape of 45° hole  230  could be any shape, including, at a minimum, a rectangular shape having a slightly greater width and thickness to permit a precise slide fit with an exposed head of a typical hardwood staple. However, a round hole is preferred so that it may be formed using a standard drill. 45° hole  230  is sized to accommodate a cylindrical rod  300  having a hammering head  305  with a thickness  302  greater than that of the thickness of a typical hardwood staple. A thicker hammering head  305  is preferred because it is easier to strike and will not bend as easily as a rod that was only the thickness of a typical hardwood staple. However, 45° hole  230  (and rod  300 ) are preferably not wider than the width of a typical hardwood staple. This is so a staple slot  250  can be formed by the addition of two parallel rectangular channels  255 ,  260 . Channels  255 ,  260  have a precise width and thickness such that they together form a rectangular staple slot  250 . The shape of staple slot  250  creates a precise slide fit to accept and support an exposed staple head during the process of finish hammering. 
         [0031]    Channels  255 ,  260  have their center on the same center  240  as 45° hole  230  and are thus bisected by the same 45° bisecting plane. Channels  255 ,  260  are formed in 45° angle hole  230  all the way down to staple insertion edge  220 . Thus, channels  255 ,  260  and staple slot  250  are also bisected by the line formed by staple insertion edge  220 . As more clearly shown in  FIG. 2 , a bottom view, 45° angle hole  230  and staple slot  255  are both bisected by the line formed by staple insertion edge  220 , placing the staple slot at the optimal location for receiving an exposed hardwood staple head. 
         [0032]    As shown in  FIG. 1 , set tool  100  includes a cylindrical rod  300  with an outside diameter  302  that slides within the 45° angle hole  230 . Rod  300  has a centerline  330  and is bisected by a plane  335  through a diameter of rod  300 . Rod  300  has a hammering head  305  on one end, and a staple driving head  310  on its opposite end. Staple driving head  310  has relieved edges  315 ,  320 . As shown in greater detail in  FIG. 3 , relieved edges  315 ,  320  form an included angle in the area of 75-90°. The vertex of this included angle is centered on centerline  330  of rod  300 . Relieved edges  315 ,  320  allow staple driving head  310  to enter the external angle formed by the outer edge of the hardwood plank, and the tongue of the plank. As shown in  FIG. 1 , a staple receiving groove  340  is formed in driving head  310  for receiving an exposed staple head. As shown in  FIG. 3 , staple receiving groove  340  is bisected by centerline  330 . As shown in  FIG. 1 , staple receiving groove  340  is also bisected by plane  335 . 
         [0033]    As previously explained, the thickness of rod  300  is greater than the thickness of a typical hardwood staple. As shown in  FIG. 3 , the full thickness  302  of rod  300  is greater than the thickness of a typical hardwood staple. The width of the staple is approximately represented by staple receiving groove  340  (dimension  303 ). 
         [0034]    As shown in  FIG. 1 , near staple driving end  310  are two guide nubs  345 ,  350 . Guide nubs  345 ,  350  are formed by insertion of a cylindrical pin  355  through a hole just behind staple receiving groove  340 . As shown in  FIG. 3 , cylindrical pin  355  is centered on and bisected by the same centerline  330  as staple receiving groove  340 . Thus, as shown in  FIG. 1 , pin  355  and guide nubs  345 ,  350  will also be bisected by plane  335 . 
         [0035]    As shown in  FIG. 4 , when set tool  100  is assembled, rod  300  is slidably inserted into 45° hole  230  in body  200 . Guide nubs  345 ,  350  extend from rod  300  such that they may enter the two channels  255 ,  260  forming staple slot  250  inside 45° hole  230 . The staple driving end  310  of rod  300  is guided by guide nubs  345 ,  350  to the exposed head of the hardwood staple. Staple receiving groove  340  of staple driving end  310  fits over the exposed hardwood staple head, forming a supportive driving surface. Body  200  has a body base surface  205 . Extending downward from body base surface  205  is arm  225 . Arm  225  forms a stop surface  215 . Stop surface  215  forms an external angle of about 75° in relation to body base surface  205 . Staple insertion edge  220  is located at the bottom of stop surface  215 . Arm base surface  225  is parallel to body base surface  205 . 
         [0036]      FIG. 7  is a cross sectional view of the set tool properly located over an exposed staple head and against the edge of a hardwood plank. Hardwood staple  10  is partially driven into the side of the plank  11 , leaving an exposed staple head  2 . To position set tool  100 , the user first puts exposed staple head  2  into staple slot  250 . The user rests body  200  on a top face of plank  11  on body base surface  205 , and presses staple insertion edge  215  of body  200  into the vertex of the external angle formed by the outer edge  14  of the plank, and the tongue  15  of the plank. Arm base surface  225  rests on the tongue  15  of plank  11 . Rod  300  is inserted into 45° hole  230  with the two guide nubs formed by pin  355  inserted into the two channels forming staple slot  250 . Thus, staple receiving groove  340  in the staple driving end  310  of rod  300  is guided to exposed staple head  2 . Once the staple receiving groove  340  contacts exposed staple head  2 , the user hammers on hammering end  305 , and the exposed staple head  2  is finished hammered into the side of plank  11 . The exposed staple head will not bend over due to close support provided by the staple slot  250 . 
         [0037]    A number of alternatives may be adopted to create a plank top set tool for hardwood staples. As previously explained, it is preferred that the rod for finish hammering the staple be thicker than the thickness of the hardwood staple, in order to allow for easy hammering. However, in other alternatives, the thickness of the rod need only be about as thick as a hardwood staple. As also previously explained, for efficient manufacturing, it is preferred that the 45° angle hole be circular so that it could be machined using standard drills, and for the rod to be cylindrical. However, the 45° angle hole could be formed in a different shape, such as a triangle or square, and have a rod of corresponding shape. The use of a square or triangular 45° angle hole and corresponding rod would prevent the rod from rotating within the hole, thus eliminating the need for guide nubs and a staple slot running the full length of the 45° angle hole. 
         [0038]    In a preferred embodiment, the rod includes a staple driving head having relieved edges forming an included angle shape, and an integral staple receiving groove formed in the relieved end. This configuration is preferred due to low manufacturing cost due to minimal parts. In another alternative, the set tool could include a staple driving head with a thin tip extension. As shown in  FIG. 9 , rod  500  has a staple driving head  510  that includes a slot  570 . Inserted into slot  570  is a tip  575  that could be formed as a metal stamping from a thin piece of metal. Tip  575  has a staple receiving groove  580  formed in its end. Tip  575  is fastened to rod  500  by press fitting a pin  590  into a hole  585 . Tip edges  577 ,  579  may form guide nubs running within a staple slot to guide the tip  575  to the top of the exposed hardwood staple head. In the finish hammering process, tip  575  is thin and easily enters the external angle formed by the outside edge of the hardwood plank, and the tongue of the plank. However, relieved edges  595 ,  597  in staple driving end  510  are still needed to allow the whole staple driving end to enter this external angle formed by the outer edge of the plank, and the tongue of the plank. 
         [0039]    A thin tip such as tip  575  can have several advantages if a higher priced, more durable, and more functional set tool is desired. Rod  500  can be formed as a body  505  from a first, comparatively soft material having sufficient impact resistance for safe hammering at hammering end  507 . Tip  575  may be made from a harder material which could be precision ground on the end to form a staple receiving groove  580  that conforms with the longitudinally rounded shape of the crown of the hardwood staple. Tip  575  can better drive the exposed hardwood staple head below flush into the side of hardwood plank. The lack of any exposed hardwood staple head whatsoever at the tongue and groove joint can make it easier to get the joint between planks together. 
         [0040]    In another alternative, the rod of the set tool could incorporate a means to protect the hand from off center blows from a hammer. 
         [0041]    In another alternative, the body of the set tool could incorporate a prying means for standing up accidentally bent over staples, or prying them out if necessary. 
         [0042]    In another alternative, a felt pad may be added to the body base surface of the body to protect the face of the hardwood plank from being scratched. 
         [0043]    The embodiments may be characterized in a number of different ways. For example, the device may be sold as a complete set tool, including both a body and a rod. Alternatively, the body and rod may be sold separately, requiring final assembly by a user.