Patent Publication Number: US-6659141-B2

Title: Tool for bending a ceiling support rod

Description:
FIELD OF THE INVENTION 
     The present invention relates to tools for bending structural elements, and more particularly, to a tool for bending ceiling support rods. 
     BACKGROUND OF THE INVENTION 
     Many offices and retail establishments include suspended ceilings, wherein a horizontal framework suspended a predetermined distance from the floor supports a ceiling material, such as drywall or ceiling tiles. The framework is suspended from a support ceiling structure by support rods. Support rods for supporting a drywall ceiling are typically of a larger gauge than support rods used for supporting an acoustic tile ceiling. Each support rod is bent at a predetermined location to support part of the framework. As will be appreciated, each support rod must be bent at the same distance from the floor to assure a level ceiling. 
     The present invention provides a tool for bending ceiling support rods that support a ceiling framework. 
     SUMMARY OF THE INVENTION 
     In accordance with a preferred embodiment of the present invention, there is provided a tool for bending ceiling support rods. The tool includes a first lever having a first handle portion and an associated first jaw portion. The first jaw portion has two, spaced-apart jaw members, each having a jaw edge. A second lever having a second handle portion and an associated second jaw portion is provided. The first lever and the second lever are pivotally mounted to each other, wherein the first jaw portion and the second jaw portion are opposite each other and are movable relative to each other when the first and second handle portions are compressed. The second jaw portion moves along a path between the jaw edges of the jaw members of the first jaw portion when the handle portions are compressed toward each other. The second jaw portion is movable from a first position wherein the second jaw portion is spaced-apart from the first jaw portion to a second position wherein the second jaw portion is disposed between the jaw edges of the first jaw portion. 
     In accordance with a preferred embodiment of the present invention, there is provided a tool for bending ceiling support rods. The tool includes a first lever and a second lever. The first lever has a first handle portion and an associated first jaw portion, the first jaw portion has a contoured surface. The second lever has a second handle portion and an associated second jaw portion, the second jaw portion has an edge. Means are provided for pivotally mounting the first lever with the second lever, wherein the first jaw portion and the second jaw portion are opposite each other and are movable relative to each other when the first and second handle portions are compressed. The edge of the second jaw portion is movable toward the contoured surface of the first jaw portion when the first and second handle portions are compressed toward each other. 
     It is an object of the present invention to provide a tool for bending ceiling support rods that support a suspended ceiling. 
     It is another object of the present invention to provide a tool for bending ceiling support rods that is lightweight and easy to use. 
     It is another object of the present invention to provide a tool as defined above wherein the tool may be used and operated with one hand. 
     A still further object of the present invention is to provide a tool as defined above that is formed of two levers, each lever being formed of from a flat, metallic sheet. 
     These and other objects will become apparent from the following description of a preferred embodiment taken together with the accompanying drawings and the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention may take physical form in certain parts and arrangement of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein: 
     FIG. 1 is a perspective view of a tool for bending ceiling support rods, illustrating a preferred embodiment of the present invention; 
     FIG. 2 is a front elevational view of the rod shown in FIG. 1; 
     FIG. 3 is a top plan view of the tool shown in FIG. 2; 
     FIG. 4 is a left elevational view of the tool shown in FIG. 2; 
     FIG. 5 is a right elevational view of the tool shown in FIG. 2; 
     FIG. 6 is a rear elevational view of the tool shown in FIG. 2; 
     FIG. 7 is a bottom plan view partially in section of the tool shown in FIG. 2; 
     FIG. 8 is a view similar to FIG. 2, showing the tool locked in a closed position; 
     FIG. 9 is an end view of the tool showing the operative end of the tool in a first position relative to a ceiling support rod to be bent; 
     FIG. 10 is an end view of the tool showing the operative end of the tool in a second position at the moment when the ceiling support rod is bent by compression of the tool; 
     FIG. 10A is a view of a bent ceiling support rod after release from the tool; 
     FIG. 11 is a developed view of a preformed metal piece used to form a first lever of the tool; and 
     FIG. 12 is a developed view of a preformed metal piece used to form a second lever of the tool. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENT 
     Referring now to the drawings wherein the showings are for the purpose of illustrating the preferred embodiment of the invention only, and not for the purpose of limiting same, a tool  10  for bending ceiling support rods is shown. Tool  10  includes a first lever  20  and a second lever  40 . Second lever  40  is pivotally mounted to first lever  20  by a pin  60  that allows pivotal movement of first lever  20  relative to second lever  40 . 
     First lever  20  includes a handle portion  22  and a jaw portion  24 . Jaw portion  24  has a generally contoured surface  24   a  that is used to bend a support rod, as shall be described in greater detail below. While surface  24   a  may assume a number of different concave or inwardly curved or rounded shapes, in the embodiment shown, jaw portion  24  includes two (2) jaw members  26 ,  28 . In the embodiment shown, jaw members  26 ,  28  are disposed at an angle relative to each other and joined together to form jaw portion  24 . Jaw portion  24  is V-shaped and defines a generally V-shaped surface  24   a . V-shaped surface  24   a  defines an angle of about 90°. Jaw members  26 ,  28  have outer edges  26   a ,  28   a , respectively, that are spaced apart, as best seen in FIG.  4 . Edges  26   a ,  28   a  are parallel to each other. 
     A slot or opening  32 , best seen in FIG. 5, is formed through first lever  20  between handle portion  22  and jaw portion  24 . Slot portion  32  is dimensioned to receive second lever  40  therethrough, as shall be described in greater detail below. Second lever  40  includes a handle portion  42  and jaw portion  44 . Jaw portion  44  is basically a flat, planar element having an edge  44   a . A notch or recess  46  is formed along jaw edge  44   a , as best seen in FIGS. 6 and 11. Jaw portion  44  is oriented to lie in a plane that bisects jaw portion  24  of first lever  20 . In this respect, second jaw portion  44  bisects surface  24   a  of first jaw portion  24 . 
     First lever  20  is pivotal relative to second lever  40  such that edge  44   a  of jaw portion  44  is parallel to jaw edges  26   a ,  28   a  of jaw portion  24  and is movable therebetween. In this respect, planar jaw portion  44  basically bisects and is movable toward surface  24   a  of first jaw portion  24 , and engages surface  24   a  at the point where jaw members  26 ,  28  are joined. In this respect, first lever  20  and second lever  40  are movable between a first opened position, wherein jaw portion  24  is spaced apart from jaw portion  44  when handle portion  22  of first lever  20  is spaced apart from handle portion  44  of second lever  40 , and a second, closed position wherein jaw portion  44  abuts surface  24   a  of jaw portion  24  when handle portion  22  of first lever  20  and handle portion  42  of second lever  40  are compressed together. 
     A biasing element  70  is provided to bias handle portion  22  and handle portion  42  away from each other. In the embodiment shown, biasing element  70  is an elongated length of a resilient, spring metal having a normal, straight configuration. Biasing element  70  has two (2) leg sections  70   a ,  70   b  that engage respectively handle portions  22 ,  42  and bias handle portions  22 ,  42  away from each other. 
     A locking mechanism  80  is provided to lock first lever  20  and second lever  40  in a closed position, wherein tool  10  is in a compact configuration with handle portion  22  of first lever  20  adjacent to handle portion  42  of second lever  40 . Locking mechanism  80  is comprised of a locking lever  82  that is pivotally mounted to second lever  40  by a pin  92 . Locking lever  82  has a first arm  82   a  and second arm  82   b . First arm  82   a  has a free end  82   c . Second arm  82   b  has an end that is bent to define a tab  82   d  that extends generally perpendicular to second arm  82   b . The operation of the locking mechanism  80  shall be described below. 
     Referring now to FIGS. 11 and 12, tool  10  shall further be described with respect to a method of forming the same. Tool  10  is preferably formed of a metallic material, and may be formed of a number of different processes, such as casting or forging. In the embodiment shown, tool  10  is formed from a flat, metallic sheet material, wherein first lever  20  and second lever  40  are formed respectively from a pair of flat, preforms  120 ,  140  that are die stamped from a metallic sheet material. 
     First lever preform  120 , best seen in FIG. 12, includes a preform handle portion  122  and a preform jaw portion  124 . Handle portion  122  is basically rectangular in shape and includes side sections  122   a  having straight edges  122   b  and intermediate sections  122   c . As seen in FIG. 12, holes  126  are formed in sections  122   c . Slot  32 , as described above, is formed in first lever preform  120 . A pair of spaced-apart holes  126 , dimensioned to receive pivot pin  60 , are also formed in first lever preform  120 . First lever preform  120  is dimensioned to be bent along a central axis, designated  132  in the drawings, by a die forming operation or the like, to bend lever preform  120  into a generally U-shaped configuration. Side sections  122   a  of preform handle portion  122  are adapted to be bent along bend lines  134  wherein straight edges  122   b  of side section  122   a  are brought together to form a closed handle portion  22 , as best illustrated in FIG.  7 . Jaw portion  124  of first lever preform  120  is bent along bend axis  152  to define V-shaped jaw portion  24  and shaped surface  124   a . In the embodiment shown, preform jaw portion  124  is bent to define jaw members  26 ,  28 , wherein jaw members  26 ,  28  are flat, planar elements that are oriented at an angle of about 90° relative to each other. As will be appreciated by those skilled in the art from a further reading of the specification, jaw members  26 ,  28  may be disposed relative to each other at angles less than 90°. After V-shaped jaw portion  24  is formed, V-shaped jaw portion  24  is bent slightly toward the position of jaw portion  44 , as best seen in FIGS. 2 and 8. Bending of jaw portion  24  relative to formed handle portion  22  produces bend lines illustrated and designated  136  in FIG.  12 . 
     Lever preform  120  is further shaped and formed to cause intermediate sections  122   c  to be bent and shaped along bend lines  138  into a generally U-shaped configuration wherein the portion of intermediate sections  122   c  having holes  126  therethrough are basically parallel to each other, as best seen in FIG.  4 . 
     Referring now to FIG. 11, second lever preform  140  is shown. Second lever preform  140  has a preform handle portion  142  and a preform jaw portion  144 . Preform jaw portion  144  is shaped to define jaw portion  44  and notch  46  as discussed above. A hole  146  is formed in lever preform  140  to receive pivot pin  60 . A second hole  148  is formed in lever preform  140  for mounting locking mechanism  80 . Preform handle portion  142  is dimensioned to be bent along a bend axis  152 , to define a generally U-shaped handle portion  42 , as best seen in FIG.  7 . 
     Tool  10  is assembled by inserting jaw portion  44  of second lever  40  through slot  32  and first lever  20 . Hole  146  in second lever  40  is aligned with holes  126  in first lever  20 , and pin  60  is inserted therethrough. The end of pin  60  is flared, as conventionally known, to maintain and lock pin  60  in position, and to allow pivotal movement of first lever  20  relative to second lever  40 . In a similar fashion, locking mechanism  80  is mounted to second lever  40  by a pin  92  to allow pivotal movement of locking lever  82  relative to second lever  40 . 
     Biasing element  70  is attached to tool  10  by inserting leg section  72   a  of biasing element  70  through opening  32  in first lever  20  into the space defined by first handle portion  22 , as best illustrated in FIG.  2 . As indicated above, in the embodiment shown, biasing element  70  is an elongated length of spring metal having a normally straight configuration. Leg section  72   b  is then bent relative to leg section  72   a  and positioned into the space defined by U-shaped handle portion  42 , as best seen in FIG.  2 . Bending biasing element  70  from its normal straight configuration produces a biasing force on handle portions  22 ,  42  that biases handle portions  22 ,  42  away from each other, as biasing element  70  tries to resume its normal, straight configuration. 
     In the embodiment shown, polymer handle grips  222 ,  242  are provided on handle portions  22 ,  42 , respectively. Handle grips  222 ,  242  may be prefromed and assembled onto handle portions  22 ,  42 , but in a preferred embodiment, handle grips  222 ,  242  are formed by inserting handle portions  22 ,  42  into a bath (not shown) of a heated, softened polymer material, removing the handles from the bath and allowing the polymer material attached to handle portions  22 ,  42  to cool and harden, as is conventionally known. 
     Tool  10  is dimensioned to be held and used by one hand. In this respect, tool  10  is dimensioned to have an overall length of about 6 to 12 inches. In a preferred embodiment, tool  10  is about 8½ inches in length. 
     Referring now to the use and operation of tool  10 , tool  10  is used for bending a ceiling support rod for supporting a suspended ceiling. As indicated above, to insure a level ceiling, each support rod must be bent at the same distance from the floor surface to insure a level ceiling. It is typically known to establish the location where the rods are to be bent by using a laser elevated above the floor that shoots a horizontal laser beam across a room. The laser beam establishes a reference mark on each of the support rods where a support rod is to be bent. 
     FIGS. 9 and 10 schematically illustrate the use of tool  10  in bending a ceiling support rod, designated  402  in the drawings. A laser device  412  is schematically illustrated resting on a support surface  414 . Laser device  412  is positioned and oriented to emit a horizontal beam of light  422  that intersects support rod  402  and establishes the desired location to bend support rod  402 . With jaw portions  24 ,  44  spaced apart, an installer positions tool  10  such that jaw portion  44  of second lever  40  is aligned with light beam  422 , as illustrated in FIGS. 9 and 10. In this position, support rod  402  is disposed within notch  46  of jaw portion  44 , and jaw edge  44   a  is disposed on one side of the support rod (aligned with the laser beam) and jaw edges  26   a ,  28   a  are disposed on the opposite side of the support rod. The installer then compresses handle portions  22 ,  42  together thereby closing jaw portions  24 ,  44  wherein jaw edge  44   a  forces support rod  402  against jaw edges  26   a ,  28   a  and begins to bend support rod  402  by forcing support rod  402  toward V-shaped surface  24   a  defined by jaw portion  24 . Further compression of handle portions  22 ,  42  forces support rod  402  against V-shaped surface  24   a  of jaw portion  24  and permanently bends support rod  402  to 90° or more relative to the upper portion of the support rod, as illustrated in FIG.  10 . By aligning the planar jaw portion  44  with laser beam  422 , each support rod  402  supporting a ceiling structure can be bent at the same elevation as established by laser beam  422 . As indicated above, tool  10  is preferably dimensioned for use by one hand. 
     The present invention thus provides a lightweight, simple tool that greatly accelerates installation of a suspended ceiling structure by enabling rapid bending of support rods by an installer using only one hand. A tool as described above is capable of efficiently bending support rods ranging in gauge size from  9  to  12 , as is conventionally known for supporting drywall and acoustic tile ceilings. (At gauges above  12 , tool  10  may not be required as such gauges may be bendable by hand). By freeing the other hand of the installer, the installer can use his free hand for balance or to manipulate the bent section of the support rod. 
     The foregoing description is a specific embodiment of the present invention. It should be appreciated that this embodiment is described for purposes of illustration only, and that numerous alterations and modifications may be practiced by those skilled in the art without departing from the spirit and scope of the invention. For example, although tool  10  was described as being formed from a metallic sheet material, tool  10  may be formed from cast or forged metal parts without deviating from the present invention. Further, construction of tool  10  is not limited to the temporal order of the steps described above. Still further, while a V-shaped jaw surface was described with respect to a preferred embodiment, other contoured surfaces, such as by way of example and not limitation, a rounded, parabolic or elliptical concave surface having jaw edges may also find advantageous application in the present invention. It is intended that all such modifications and alterations be included insofar as they come within the scope of the invention as claimed or the equivalents thereof.