Patent Publication Number: US-10780480-B1

Title: Sheet metal straightening device

Description:
CROSS REFERENCE TO RELATED APPLICATIONS AND INCORPORATION BY REFERENCE 
     [Not applicable] 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable. 
     INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISK 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The field of the invention relates generally to systems and methods for repairing deformed structures such as automobile bodies and body parts. More specifically, in embodiments, the invention relates to systems and methods for producing a desired surface in a vehicle body or body part in or near a location on the structure in which a hole is located during the course of repair of a body part, after the body part has been subjected to unwanted disfiguring forces that have resulted in undesired protuberances, creases, bends, and other disfigurements and deformities that cause the body part to have a surface shape and appearance that is not in conformity with a desired surface shape. The desired surface shape may be flat or curved along one or more cross sections. The body part may, but does not necessarily, comprise sheet metal structures. 
     2. Background Art 
     There are many scenarios in which it is desired to return a disfigured sheet structure to a desired surface shape. Such disfigured sheet structures may result, for example, in the case in which vehicle body parts have been subjected to disfiguring forces resulting from collisions between vehicles, or between a vehicle and another stationary or moving object. In some cases the disfiguring forces causing the unwanted disfigurement may result from other body or repair work that is being performed upon a vehicle. In another non-limiting case, the disfiguring forces may result from severe weather, such as may be caused by the impact of hail or falling ice on a sheet structure, leaving unwanted dents in the sheet structure that cause the sheet structure to have a surface shape and appearance that is not in conformity with a desired surface shape, which may be flat or cured along one or more cross sections. Non-limiting examples of sheet structures that have been disfigured and thus have a surface shape that is not in conformity with a desired planar shape due to hail damage are automobile bodies, motorcycle body parts, and metal roofs such as, for example, corrugated metal roof panels and the like. Often such structures contain holes, around which the sheet structure has been deformed. Such deformities may occur during vehicle body work when panels are detached from a vehicle. In many cases, it is required that such deformities be substantially removed from surfaces that are not feasible to place in a floor machine press due to the shape of the part, or the construction of the part, or for other reasons. 
     What is needed in the art, therefore, is an apparatus and/or method adapted to quickly and efficiently straightening of deformities surrounding a hole in a sheet metal surface for which it not feasible to use a floor machine press, substantially and quickly returning the sheet metal surface to a desired surface shape. 
     BRIEF SUMMARY OF THE INVENTION 
     The present invention comprises an apparatus and method that have one or more of the following features and/or steps, which alone or in any combination may comprise patentable subject matter. 
     In accordance with one embodiment of the present invention, the invention comprises a hole straightening apparatus, comprising: a handle pivotally attached to a frame; a moving jaw comprising an anvil surface, wherein the moving jaw is slidingly engaged with a surface of the frame; a stationary jaw comprising an anvil surface wherein the stationary jaw is attached to the frame; and a lever pivotally attached to the frame and pivotally attached to the handle; wherein when the handle is motivated towards the frame, a surface of the lever is in contact with and motivates the moving jaw along a surface of the frame towards the stationary jaw; the hole straightening apparatus having a closed state wherein the anvil surface of the moving jaw is in contact with, and exerts a compressive force against, the anvil surface of the stationary jaw; and the hole straightening apparatus having an open state wherein the anvil surface of the moving jaw is motivated away from the anvil surface of the stationary jaw, creating an anvil gap between the he anvil surface of the moving jaw and the anvil surface of the stationary jaw; and wherein the stationary anvil has a width less than a dimension of a hole in a sheet metal structure desired to be straightened. 
     In embodiments, the moving anvil may have a width less than a dimension of a hole in a sheet metal structure desired to be straightened. 
     In embodiments the stationary jaw may be fabricated from sheet steel. 
     In embodiments, the stationary jaw may be interchangeable with other stationary jaws of differing dimension to accommodate a variety of dimensioned or shaped holes in a sheet structure to be straightened. In embodiments, the stationary jaw may be releasably attached to the frame. 
     In embodiments the moving jaw may be fabricated from sheet steel. 
     In embodiments the invention may comprise a threaded compression force adjusting rod threadingly engaged with the frame and protruding into the frame, wherein a distal surface of the threaded compression force adjusting rod is in contact with a surface of a lever pivotally attached to the handle such that when the threaded compression force adjusting rod is rotated so as to protrude further into the frame, the compressive force is increased when the hole straightening apparatus is in a closed state, and when the distal surface of the threaded compression force adjusting rod is rotated so as to proceed further out of the frame, the compressive force is decreased when the hole straightening apparatus is in a closed state. 
     The present method and device of the invention overcome the shortcomings of the prior art by providing a handheld tool for quick and efficient straightening of deformities surrounding a hole in a sheet metal surface, substantially and quickly returning the sheet metal surface to a desired surface shape. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings, which are incorporated into and form a part of the specification, illustrate one or more embodiments of the present invention and, together with the description, serve to explain the principles of the invention. The drawings are only for the purpose of illustrating the preferred embodiments of the invention and are not to be construed as limiting the invention. In the drawings: 
         FIG. 1  depicts a perspective view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention in a closed state, in which the moving anvil has been fully motivated against the stationary anvil of the invention. 
         FIG. 2  depicts a perspective view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention in an open state, in which the moving anvil has been motivated away from the stationary anvil of the invention. 
         FIG. 3  depicts a perspective view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention in a closed state, in which the moving anvil has been fully motivated against the stationary anvil of the invention of the invention. 
         FIG. 4  depicts a perspective view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention in an open state, in which the moving anvil has been fully motivated against the stationary anvil of the invention of the invention. 
         FIG. 5  depicts a partial cross section side view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention in an open state, in which the moving anvil has been fully motivated away from the stationary anvil of the invention of the invention. 
         FIG. 6  depicts a partial cross section side view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention in a closed state, in which the moving anvil has been fully motivated against the stationary anvil of the invention of the invention. 
         FIG. 7  depicts an exploded view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention. 
         FIG. 8  depicts a side view of a non-limiting exemplary embodiment of a hole straightener of the invention, in which the hole straightener is being used to straighten the deformed edges of a hole in a sheet-metal structure, in which the moving anvil has been motivated towards the stationary anvil, capturing the deformed edges of the hole to be straightened between the moving anvil and the stationary anvil such that continued applied pressure by the moving anvil against the deformed sheet-metal structure, resisted by the stationary anvil, causes the deformed sheet-metal structure to be returned to a substantially non-deformed state. 
         FIG. 9  depicts a cross section view of a sheet-metal structure containing a deformed hole to be straightened. 
         FIG. 10  depicts a cross section view of an embodiment of the sheet metal straightener of the invention in use, in which the stationary anvil is depicted as having been inserted into the hole to be straightened and in which the moving anvil has not yet begun to be motivated against the deformed sheet metal structure, i.e., this view depicts a hole straightener of the invention just prior to the application of straightening forces to the deformed sheet metal structure by the hole straightener. 
         FIG. 11  depicts a cross section view of a deformed sheet-metal structure containing a hole prior to the application of straightening forces by the hole straightening apparatus of the invention. 
         FIG. 12  depicts a cross section view of a repaired sheet-metal structure containing a hole after to the application of straightening forces by the hole straightening apparatus of the invention. 
     
    
    
     In the figures, like callout numbers refer to like features. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The following documentation provides a detailed description of the invention. 
     Although a detailed description as provided in the attachments contains many specifics for the purposes of illustration, anyone of ordinary skill in the art will appreciate that many variations and alterations to the following details are within the scope of the invention. Accordingly, the following preferred embodiments of the invention are set forth without any loss of generality to, and without imposing limitations upon, the claimed invention. Thus the scope of the invention should be determined by the appended claims and their legal equivalents, and not merely by the preferred examples or embodiments given. 
     As used herein, “disfiguring forces” includes within its meaning one or more forces that, when acting upon a sheet structure, cause the structure to be deformed such that a surface of the sheet structure no longer conforms to a desired surface shape. 
     As used herein, “desired surface shape” includes within its meaning any desired surface shape. A non-limiting example of a desired surface shape is a plane, which plane may be flat or may be a curved plane. As another non-limiting example, the desired surface shape may be that of a curved plane that is characterized by one or more curvilinear cross sections of the sheet structure. The desired surface shape may be any surface shape desired by a user. 
     As used herein, “hole to be straightened” and “sheet metal structure to be straightened” refer to a sheet metal surface having undesired deformities that depart from a desired surface shape, for which the removal of the deformities such that the sheet metal structure is substantially returned to a desired surface shape (“straightening”) is desired. Such undesired deformities may be the result of the prior application of disfiguring forces to a sheet structure. 
     As used herein, “closed state” means that state in which moving jaw  106  and moving anvil  105  have been motivated in the direction of arrow B, as depicted in the figures, towards stationary anvil  113  such that an anvil surface of moving anvil  105  is in contact with and is pressed against an anvil surface of stationary anvil  113  with a closing force F. The compressive force F pressing moving anvil  105  into stationary anvil  113  is also the force that is applied to the upper and lower surfaces of a deformed sheet metal structure for which it is desired to straighten the edges of a hole disposed in the sheet metal structure. 
     As used herein, “open state” means that state in which moving jaw  106  and moving anvil  105  have been motivated in the direction of arrow B, as depicted in the figures, away from a stationary anvil  113  such that an anvil surface of moving anvil  105  is no longer in contact with, and is motivated away from, the anvil surface of stationary anvil  113 . In the open state, there is no force asserted between the anvil surfaces of stationary anvil  113  and moving anvil  105 . When the hole straightener of the invention is disposed in an open state, it is possible to motivate stationary anvil  104  through a hole to be straightened and to translate stationary anvil  104  along the sheet-metal surfaces surrounding the hole to be straightened, sequentially straightening the sheet metal surrounding the hole, until the sheet metal surrounding the hole has been substantially returned to a desired surface shape. 
     Referring now to  FIGS. 1 and 3 , views of the sheet metal straightening apparatus of the invention  001  are depicted in which the invention is disposed in a closed state in which moving jaw  106  and moving anvil  105  have been motivated fully into a closed state.  FIG. 1  depicts an embodiment of the hole straightening apparatus of the invention from a side perspective view.  FIG. 3  depicts an embodiment of the hole straightening apparatus of the invention from a rear perspective view. In the closed state as depicted in  FIGS. 1 and 3 , handle  101  has been motivated in the direction of arrow A towards frame  100  about pivot point  120  (depicted in  FIG. 5 ). Pivot point  120  may comprise a cylindrical pin, axle, screw, shoulders screw or other substantially cylindrical element that allows the rotation of pivot handle  100  about moving jaw  106  at pivot point  120 . The operation of the hole straightening apparatus in transitioning from an open state to a closed state, and vice versa, is more fully described below in relation to  FIG. 5 . Stationary jaw  108  may be attached to frame  100  by mechanical attachments  107 . Mechanical attachments  107  may take any form known in the art such as threaded fasteners, press pins, rivets, or any other means for attaching one mechanical component to another. In embodiments, mechanical attachments  107  may easily removable with or without tools, such as, by way of example and not by way of limitation, threaded fasteners, pins having retaining features such as Cotter pins, spring loaded ball detent arrangements, or the like, in order to allow stationary jaw  108  to be removably attached to frame  100 . Such removable attachment of stationary jaw  108  to frame  100  enables the stationary jaw  108  and stationary anvil  104  to be removed and replaced by other embodiments of stationary jaw  108  and stationary anvil  104  in which stationary anvil  104  width W (not shown in  FIG. 1 , but shown in  FIG. 7 ) is adapted to pass through openings Y of varying width forming a part of hole  201  in a sheet metal structure to be straightened  200  (not depicted in  FIG. 1  but depicted in  FIGS. 11 and 12 ). In this manner stationary jaw  108  and stationary anvil  104  may be fabricated in any number of interchangeable embodiments in order to adapt the invention to various size holes  201  or to adapt the invention to various configurations of sheet metal structures to be straightened. In embodiments, mechanical attachments  107  may take the form of permanent attachments such as weldments, chemical bonding or any other means of attachment. Stationary jaw  108  may be attached to a stationary anvil bracket  113  to which stationary anvil  104  is attached. Stationary anvil bracket  113  and stationary anvil  104  may, but do not necessarily, form a unitary structure. In embodiments, stationary anvil bracket  113  and stationary anvil  104  may be formed from a single portion of sheet material. Moving anvil surface F and stationary anvil surface E are depicted for reference. Pivot points  111  and  102  are depicted for reference. 
     Referring now to  FIGS. 2 and 4 , views of the sheet metal straightening apparatus of the invention  001  are depicted in which the invention is disposed in an open state in which moving jaw  106  and moving anvil  105  have been motivated fully into an open state, i.e., in a direction away from stationary anvil  104 .  FIG. 2  depicts an embodiment of the hole straightening apparatus of the invention from a side perspective view.  FIG. 4  depicts an embodiment of the hole straightening apparatus of the invention from a rear perspective view. In the open state as depicted in  FIGS. 2 and 4 , handle  101  has been motivated in the direction of arrow A away from frame  100  about pivot point  120  (depicted in  FIG. 5 ). Pivot point  120  may comprise a cylindrical pin, axle, screw, shoulder screw or other mechanical element, which may be, but is not necessarily, cylindrical, that allows the rotation of pivot handle  100  about moving jaw  106  at pivot point  120 . The operation of the hole straightening apparatus  001  in transitioning from a closed state to an open state, and vice versa, is more fully described below in relation to  FIG. 5 . Stationary jaw  108  may be attached to frame  100  by mechanical attachments  107 . Mechanical attachments  107  may take any form known in the art such as threaded fasteners, press pins, rivets, or any other means for attaching one mechanical component to another. In embodiments, mechanical attachments  107  may take the form of permanent attachments such as weldments, chemical bonding or any other means of attachment. Stationary jaw  108  may be attached to stationary anvil bracket  113  to which stationary anvil  104  is attached. Stationary anvil bracket  113  and stationary anvil  104  may, but do not necessarily, form a unitary structure. In embodiments, stationary anvil bracket  113  and stationary anvil  104  may be formed from a single portion of sheet material. Moving anvil surface F and stationary anvil surface E are depicted for reference. Pivot points  111  and  102  are depicted for reference. 
     Referring now to  FIGS. 5 and 6 , a side view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention  001  in an open state, in which the moving anvil  105  has been fully motivated away from the stationary anvil  104  of the invention of the invention, is depicted. In the open state, stationary anvil  104  may be motivated and articulated such that it is able to pass through a hole  201  in a deformed sheet metal structure  200  (see  FIGS. 8 and 10 ) for which straightening is desired. Stationary anvil  104  may have a width W that is smaller than a dimension of the hole  201  located in the sheet metal structure  200  for which straightening is desired. Thus, stationary anvil  104  may be articulated such that it may be motivated through the hole in the sheet metal structure as depicted further in  FIGS. 8 and 10 . Stationary anvil  104 , stationary anvil bracket  113 , and stationary jaw  108  may be fabricated as separate components and assembled by any means known in the art such as welding, chemical bonding, riveting, threaded fastener&#39;s, or the like; or, alternatively, stationary anvil  104 , stationary anvil bracket  113  and stationary jaw  108  may be a unitary structure fabricated by any means known in the art such as, for example and not by way of limitation, casting, molding, machining, additive manufacturing or any other means and method of manufacture. In an embodiment, stationary jaw  108  and stationary anvil  104  may each be fabricated from bent sheet-metal and welded or bonded together. Likewise, moving anvil  105  and moving jaw  106  may be a unitary structure fabricated by any means known in the art such as, for example and not by way of limitation, casting, molding, machining or any other means and method of manufacture. In an embodiment, moving jaw  106  may be fabricated from sheet metal. In an embodiment, moving anvil  105  may be fabricated by any means known in the art such as, for example and not by way of limitation, casting, molding, machining or any other means and method of manufacture. Stationary jaw  108  may be attached to frame  100  by attachments  107  as herein before described. Handle  101  may be rotably attached to lever  112  at attachment point  111 . When handle  101  is motivated towards frame  100  as shown by arrow A such that the hole straightening device of the invention  001  is transitioned to a closed state (see  FIG. 6  for a depiction of the closed state), the pivoting action at pivot points  111  and  120  cause moving a jaw  106  to be motivated in the direction of arrow B towards stationary anvil  104  and stationary anvil surface E as moving jaw  106  slides along surface P of frame  100  in a sliding engagement. When handle  101  is motivated away from a frame  100  as shown by arrow A such that the sheet metal straightening of the device of the invention  001  is transitioned to an open state as shown in  FIG. 5 , and the pivoting actions at points  111  and  120  cause moving jaw  106  to be motivated in the direction of arrow B away from stationary anvil  104  and stationary anvil surface E as moving jaw  106  slides along surface C of frame  100  in a sliding engagement. 
     Still referring to  FIGS. 5 and 6 , the invention  100  may further comprise a threaded compression force adjusting rod  109  that may be threadingly engaged  300  with a portion of frame  100  and protruding into frame  100 , wherein a distal surface G of the threaded compression force adjusting rod may be in contact with a surface of lever  112  that is pivotally attached to handle  101  at pivot point  111  such that when threaded compression force adjusting rod  109  is rotated so as to protrude further into frame  100 , the compressive force between moving anvil surface F and stationary anvil surface E, or between moving anvil surface F, an intervening sheet structure to be straightened  200 , and stationary anvil surface E, is increased to a desired level when the hole straightening apparatus is in a closed state, and when the threaded compression force adjusting rod  109  is rotated so that the distal surface G of compression force adjusting rod  109  proceeds further out of the frame, the compressive force between moving anvil surface F and stationary anvil surface E is decreased when the hole straightening apparatus is in a closed state. In  FIG. 6 , a side view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention  001  in a closed state, in which moving anvil  105  has been fully motivated towards stationary anvil  104  of the invention of the invention, is depicted. Threaded compression force adjusting rod  109  may comprise a knurled knob  110 . In this manner, a user may adjust the amount of force used to straighten a sheet structure to be straightened  200  that is captured between moving anvil surface F and stationary anvil surface E when the invention is in a closed state by rotating threaded compression force adjusting rod  109  in its threaded engaged with frame  100  so as to translate distal surface G of compression force adjusting rod  109  further into frame  100  (increasing the compressive force on sheet structure to be straightened  200 ), or rotating threaded compression force adjusting rod  109  in its threaded engaged with frame  100  so as to translate distal surface G of compression force adjusting rod  109  further out of frame  100  (decreasing the compressive force on sheet structure to be straightened  200 ). 
     Referring now to  FIG. 7 , an exploded view of non-limiting exemplary embodiment of the invention is depicted. Stationary anvil  104 , stationary anvil bracket  113 , and stationary jaw  108  may be attached to frame  100  at attachment points  107 . Moving jaw  106  may be rotably attached to pivot point  120  of handle  101 . Handle  101  may be attached to lever  112  at pivot point  111 . Threaded compression force adjusting rod  109  may be threadingly engaged with, and protrude into, frame  100 . 
     Referring now to  FIG. 8 , a side view of a non-limiting exemplary embodiment of a sheet metal straightener of the invention  001 , in which hole straightener  001  is being used to straighten the deformed edges of a hole  201  in a sheet-metal structure to be straightened  200 , is depicted. Moving anvil  105  has been motivated towards the stationary anvil  104 , capturing the deformed edges of deformed sheet metal around hole  201  between moving anvil surface F and stationary anvil E such that continued applied compressive force by the moving anvil against the deformed sheet-metal structure, resisted by the stationary anvil, as handle  101  is motivated towards frame  100  tending to transition hole straightener to a closed state, causes the deformed sheet-metal structure to be returned to a substantially non-deformed state. In this manner the disfigured sheet metal surrounding hole  201  and sheet metal structure  200  is substantially conformed to a desired surface shape. The desired surface shape may be any shape. Although a flat planar surface is depicted in the figures of the drawings, it is within the claimed scope of the invention that the desired surface shape may be any three-dimensional surface shape. 
     Referring now to  FIGS. 9-11 , an exemplary deformed sheet metal surface  200  that is be desired to be straightened is depicted. Deformed sheet metal surface  200  may comprise a hole  201  defined by an opening dimension Y. It is not necessary that hole  201  be circular; thus hole  201  may be of any shape. Sheet metal structure  200  may be deformed to a maximum dimension from a desired surface shape by a dimension R in height, and by a dimension S in width. Stationary anvil  104  may be inserted through hole  201  and motivated against a side wall of hole  201  as shown in  FIG. 10 . In  FIG. 10 , the hole straightening apparatus of the invention  001  is depicted in an open state. Moving anvil surface F is motivated towards stationary anvil surface E in the direction of arrow B when handle  101  is motivated towards frame  100  as herein discussed in relation to  FIGS. 1 through 6 . When handle  101  is motivated towards frame  100  the hole straightening apparatus of the invention transitions towards a closed state, causing a compressive force to be applied by moving anvil surface F on the one hand, and stationary anvil surface E on the other hand, capturing a portion of sheet metal structure to be straightened  200  comprising deformity I between the two anvil surfaces E and F. The compressive force causes deformity I to be substantially straightened. In operation, the user then motivates the hole straightening apparatus of the invention  001  around the edge of the opening of hole  201  while sequentially operating handle  101  from an open state to a closed estate, causing a compressive force between anvil surfaces E and F on the sheet metal of structure  200  that surrounds hole  201 . Thus, an operator sequentially straightens the deformed sheet metal surrounding hole  201  and sheet metal structure to be straightened  200  by: 1) starting with the hole straightening apparatus of the invention  001  in an open state, inserting anvil  104  through hole  201 ; 2) motivating anvil  104  towards an edge of hole  201 ; 3) motivating handle  101  towards frame  100  causing a transition towards a closed state and thereby asserting a compressive force on the sheet-metal structure  200  captured between anvil surfaces E and F as hereinbefore described, 4) transitioning the hole straightening apparatus of the invention  001  into an open state by motivating handle  101  away from frame  100 ; 5) motivating the sheet metal straightening device of the invention  001  along an edge of hole  201  to a next portion of deformed sheet-metal surrounding the opening of hole  201  and sheet-metal structure  200  to be straightened, and repeating steps 1) through 4). Steps 1) through 5) are then repeated until all of the deformed sheet metal surrounding the edge of the opening of hole  201  have been substantially straightened.  FIG. 11  depicts an initial view of a sheet metal structure  200  that has been subjected to disfiguring forces, causing deformities in the sheet metal surrounding hole  201 , and for which straightening is desired.  FIG. 12  depicts a final view of a sheet metal structure  200  that has been subjected to the above procedure for hole straightening, using the hole straightening apparatus of the invention  001 . In  FIG. 12 , the surface deformities surrounding hole  201  have been substantially removed from sheet metal structure  200  such that sheet-metal structure  200  has been substantially conformed to a desired surface shape. 
     Any of the described features may be present, in any combination, in any embodiment of the invention.