Patent Publication Number: US-2022212239-A1

Title: Geared Conduit Bender

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS 
     This application is a continuation of U.S. application Ser. No. 16/829,853, filed on Mar. 25, 2020, which is a continuation of International Application No. PCT/US2018/052428, filed Sep. 24, 2018, which claims priority to and the benefit from U.S. Provisional Application No. 62/569,087, filed Oct. 6, 2017, the contents of each of which are incorporated herein by reference in their entireties. 
    
    
     BACKGROUND OF THE INVENTION 
     The present disclosure relates generally to the field of conduit benders. The present disclosure relates specifically to a geared conduit bender that provides a mechanical advantage when bending a conduit pipe. 
     Conduit pipes are often used to conceal and protect electrical wiring. To keep the conduit pipes and wiring out of sight, the conduit pipes are often coupled to walls or ceilings. Frequently conduit pipes need to be bent to conform to a desired path, such as to match the contour of a wall or ceiling. Conduit benders, as their name implies, are used to bend the conduit pipes. 
     SUMMARY OF THE INVENTION 
     The present disclosure relates to geared conduit benders that provide a mechanical advantage when bending a conduit pipe. In one or more described embodiments, the disclosure relates to a conduit bender with a gear assembly to provide a mechanical advantage. In exchange for the mechanical advantage when bending the conduit pipe, the handle of the conduit bender needs to traverse a correspondingly increased arc distance. For example, if the gear provides a 3:1 mechanical advantage then the handle needs to sweep three times as much distance to bend the conduit pipe to the desired angle. 
     In some embodiments, a tool, such as a geared conduit bender, comprises a handle with an elongated shaft, a shoe, a link between the two, and a pinion gear. The shoe comprises a curved portion and gear teeth that extends radially inward from a top surface of the curved portion. The link comprises opposing first and second ends along a longitudinal axis, the first end rotatably coupled to the elongated shaft at a first axis of rotation and the second end rotatably coupled to the shoe at a second axis of rotation. The pinion gear is rotatably coupled to the elongated shaft and the first end of the link at the first axis of rotation. The pinion gear rotatably engages with the gear teeth of the shoe to provide a mechanical advantage when bending an elongated workpiece such as a conduit pipe. 
     In some embodiments, a tool comprises an elongated shaft, a shoe and a gear assembly. The shoe comprises a hook and a curved portion, the curved portion comprising gear teeth protruding radially inward from a top surface of the curved portion. The hook is fixedly coupled to a first end of the curved portion. The gear assembly is rotatably coupled to the elongated shaft and engages with the shoe to provide a mechanical advantage when a user applies force to the elongated shaft to bend the elongated workpiece. 
     In some embodiments a geared conduit bender comprises an elongated shaft, a link, a shoe and a pinion gear. The link is rotatably coupled to the shaft at a first end of the link. The shoe is rotatably coupled to a second end of the link. The shoe comprises gear teeth that extend radially inward from a top surface of a curved portion. The pinion gear rotatably engages with the gear teeth to provide a mechanical advantage when bending the elongated workpiece. 
     Additional features and advantages will be set forth in the detailed description which follows, and, in part, will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings. It is to be understood that both the foregoing general description and the following detailed description are exemplary. 
     The accompanying drawings are included to provide further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiments and, together with the description, serve to explain principles and operation of the various embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a geared conduit bender according to one embodiment. 
         FIG. 2  is a top view of the geared conduit bender of  FIG. 1 . 
         FIG. 3  is a side view of the geared conduit bender of  FIG. 1 . 
         FIG. 4  is a perspective view of the geared conduit bender of  FIG. 1  detailing a scale. 
         FIG. 5  is a side view of the geared conduit bender of  FIG. 1  in a first position. 
         FIG. 6  is a side view of the geared conduit bender of  FIG. 1  in a second position. 
         FIG. 7  is a side view of the geared conduit bender of  FIG. 1  with a pin disengaged from a pinion. 
         FIG. 8  is a cross-sectional view of a geared conduit bender of  FIG. 2  with a pin disengaged from a pinion. 
         FIG. 9  is a perspective side view of a geared conduit bender, according to an embodiment. 
         FIG. 10  is a perspective bottom view of the geared conduit bender of the embodiment of  FIG. 9 . 
         FIG. 11  is a side view of a geared conduit bender of the embodiment of  FIG. 9 . 
     
    
    
     DETAILED DESCRIPTION 
     Referring generally to the figures and below description, various embodiments of a tool for bending an elongated workpiece, such as a conduit bender, are shown and described. Various embodiments of the conduit bender discussed herein include an innovative gear assembly. The gear assembly provides a mechanical advantage when bending a conduit pipe, such as a conduit and/or a conduit run. As a result, less force is required to bend a conduit pipe as compared to bending a conduit using a conventional conduit bender. Additionally, the gear assembly facilitates more precise bending of a conduit pipe because the conduit pipe is bent more slowly in exchange for providing the mechanical advantage. As a result of the conduit pipe bending more slowly, it is easier for the user to stop bending the conduit pipe at a desired angle as compared to bending using a conventional conduit bender. 
     In one embodiment, the geared conduit bender has a handle, such as an elongated shaft, that is rotatably coupled to a linking component, such as a planar length of metal. The handle and a first end of the linking component are rotatably coupled together at a first axis of rotation. The handle rotates around the first axis of rotation. The second end of the linking component is rotatably coupled to arms of a shoe at a second axis of rotation. The arms extend from first and second ends of a curved portion (e.g., an arc) of the shoe that the conduit pipe is bent around. Gear teeth protrude radially inward from an interior top surface of the curved portion of the shoe (e.g., the teeth protrude or extend generally towards a center of the arc curved portion). 
     A pinion gear is rotatably coupled to the handle and the first end of the linking component at the first axis of rotation. The teeth of the pinion gear rotatably engage with gear teeth of the curved portion. When the pinion gear is rotated, the pinion gear acts upon the gear teeth of the shoe to cause the shoe to rotate. 
     In various embodiments, the gear assembly is a sun gear assembly with the pinion gear being the planet gear and the gear teeth of the curved portion being the ring gear that rotates around the pinion gear. The interaction of these gears provides a mechanical force advantage (e.g., as a force multiplier) when applying force to the elongated shaft to bend the elongated workpiece. 
     In exchange for the gear assembly acting as a force multiplier, the gear assembly bends the conduit pipe a correspondingly reduced amount. As a result, it may be necessary to perform multiple iterations of bending the conduit pipe to achieve a desired angle X of bend in the conduit pipe. In such situations when multiple iterations of bending the conduit pipe are required, a pin in the handle allows the user to disengage the handle from the gear assembly to reposition the handle for further bending of the conduit pipe. The pin protrudes from the handle through a slot in the walls of the handle near the end coupled to the linking component and the pinion gear. The slot extends longitudinally along the handle walls to allow the pin to selectively engage and disengage with the pinion gear. When a user pushes longitudinally down on the handle, the handle pin engages with the pinion gear. Rotation of the handle around the first axis of rotation correspondingly exerts a force on the shoe via the pin acting upon the gear assembly. When a user pulls longitudinally up on the handle, the handle pin disengages from the pinion gear and rotation of the handle around the first axis of rotation does not exert a force on the shoe via the pin. The pin specifically, and handle generally, can be selectively engaged or disengaged from the gear assembly to allow rotation of the handle to bend the conduit pipe. 
       FIGS. 1-8  illustrate a tool for bending an elongated workpiece, shown specifically as geared conduit bender  10 . Geared conduit bender  10  can be used to bend a variety of different conduits pipe such as metal, brass, copper, aluminum, steel, polyvinyl chloride (PVC), etc. In the illustrated embodiment, geared conduit bender  10  is capable of bending a conduit pipe to a desired angle, such as between a range of zero and ninety degrees. In other embodiments, geared conduit bender  10  is capable of bending a conduit pipe greater than ninety degrees. Geared conduit bender  10  includes handle  18 , shoe  30 , base  22 , and pinion gear  26 . 
     In one embodiment, a user manipulates handle  18  to selectively engage with pinion gear  26  to bend conduit pipe  14 . In one embodiment, handle  18  is a generally cylindrical, elongated rigid component (e.g., a rigid length of metal material) and includes first end  106  with bend adjuster  110  and second end  114  opposite first end  106  that couples to connector  118 . Both second end  114  and connecter  118  are positioned within elongated slot  94  on arm  66  of shoe  30 . Connector  118  includes base portion  122  and two prongs  126 . Base portion  122  receives second end  114  of handle  18  and includes two slots  130  opposite each other. Pin  134  extends from handle  18  through slots  130  to secure handle  18  to connector  118 . 
     By selectively interacting with pinion gear  26 , as described below, a user of geared conduit bender  10  is provided a mechanical advantage when bending conduit pipe  14 . Pinion gear  26  is rotatably coupled to shaft  102  and second flange  38  via fastener  58  at first axis of rotation  50  (best shown in  FIGS. 2-3 ). Pinion gear  26  rotates relative to base  22  about first axis of rotation  50 . Pinion gear  26  rotatably engages with rack  86  of shoe  30  via the plurality of gear teeth  28  on pinion gear  26  interlocking with the plurality of gear teeth  90  on rack  86  so that when pinion gear  26  is rotated about first axis of rotation  50 , shoe  30  is rotated about second axis of rotation  54 . 
     Shoe  30  rotates about second axis of rotation  54  relative to base  22 . Shoe  30  is rotatably coupled to second aperture  46  with fastener  58  (e.g., a bolt and nut). Shoe  30  includes curved bottom portion  62  and arm  66 . Channel  74  is configured to partially secure conduit pipe  14  as shoe  30  is rotated about second axis of rotation  54 . Channel  74  extends along bottom side (e.g., periphery)  70  of curved bottom portion  62  opposite gear teeth  90 . In various embodiments, channel  74  is sized to fit a conduit with a diameter within the range of 0.5 inches and three inches. In further embodiments, channel  74  is sized to fit any diameter of conduit. Channel  74  includes hook  78  that is fixedly coupled to one end of curved bottom portion  62  and that holds conduit pipe  14  against channel  74  as shoe  30  is rotated to bend conduit pipe  14 . On a top side  82  of bottom portion  62  is curved rack  86  ( FIG. 7 ) with a plurality of gear teeth  90  that correspond to a plurality of gear teeth  28  on the pinion  26 . 
     With reference to  FIGS. 2 and 3 , base  22  provides leverage for a user against a surface, such as the floor, when manipulating conduit bender  10 . Base  22  comprises first flange  34  that is configured to be positioned on a floor or a surface when bending conduit pipe  14 , and triangular second flange  38 . In various embodiments, first flange  34  is secured to the floor using fasteners (bolts, nails, screws, etc.) through apertures  154  (best shown in  FIG. 9 ). Base  22  further includes first aperture  42  that defines first axis of rotation  50  and second aperture  46  that defines second axis of rotation  54 . First aperture  42  is generally positioned in the middle of second flange  38  and second aperture  46  is generally positioned in the upper-most point of second flange  38 . 
     In use, handle  18  can be manipulated to selective engage with pinion gear  26  by handle  18  moving to a position where pin  134  engages pinion gear  26  ( FIG. 3 ) or a position where pin  134  does not engage gear tooth  28  on pinion gear  26  ( FIGS. 6 and 7 ). Curved rack  86  protrudes radially inward from top side  82  of curved bottom portion  62  ( FIG. 7 ) with a plurality of gear teeth  28  that engage plurality of gear teeth  28  on pinion gear  26 . Arms  66  of shoe  30  define elongated slot  94  between two bridges  98  of arms  66 . In use, handle  18  is rotated around first axis of rotation  50  through elongated slot  94 . 
     In the illustrated embodiment, rack  86  is an integral part of shoe  30 . In other embodiments, rack  86  may be a separate piece coupled to shoe  30 . In further embodiments, rack  86  may not be centered on shoe  30 . 
     As shown in  FIGS. 1-3 , pinion  26  is positioned on shaft  102  that is coupled to first aperture  42  of second flange  38  with fastener  58 . Pinion  26  rotates relative to base  22  about first axis of rotation  50 . Pinion  26  is also positioned on rack  86  of shoe  30  with the plurality of gear teeth  28  on pinion  26  interlocking with the plurality of gear teeth  90  on rack  86  so that when pinion  26  is rotated about first axis of rotation  50 , shoe  30  is rotated about second axis of rotation  54 . 
     With reference to  FIGS. 1-3 , in various embodiments handle  18  is generally cylindrical and includes first end  106  with bend adjuster  110  and second end  114  opposite first end  106  that couples to connector  118 . Both second end  114  of handle  18  and connecter  118  are positioned within elongated slot  94  on top portion  66  of shoe  30 . Connector  118  includes base portion  122  and two prongs  126 . Base portion  122  receives second end  114  of handle  18  and includes two slots  130  opposite each other. Pin  134  extends through slots  130  and handle  18  to secure handle  18  to connector  118 . Handle  18  can be moved within slots  130  to a position where pin  134  engages gear tooth  28  on pinion  26  ( FIG. 3 ) or a position where pin  134  does not engage gear tooth  28  on pinion  26  ( FIGS. 6 and 7 ). 
     Two prongs  126  protrude from connector  118  and include apertures (not shown) that are positioned on shaft  102  along first axis of rotation  50 . Two prongs  126  surround pinion gear  26  on both sides and can rotate relative to pinion gear  26  when pin  134  is not engaged in gear teeth  28  of pinion gear  26 . As such, connector  118  is rotatable about first axis of rotation  50 . Link  138  is coupled to shaft  102  and arm  66  of shoe  30  to adjust the arrangement of geared conduit bender  10 . One end  142  of link  138  is opposite end  146  along a longitudinal axis of link  138 . Link  138  is rotatably coupled at one end  142  to shaft  102  about first axis of rotation  50  and at another end  146  to base  22  about second axis of rotation  54 . Link  138  prevents pinion gear  26  and connector  118  from rotating out of alignment with first axis of rotation  50  and shoe  30  from rotating out of alignment with second axis of rotation  54 . 
     As shown in  FIG. 4 , second flange  38  of base  22  can be used as an angle indicator  150  to indicate the angle that conduit pipe  14  has been bent. Top side  82  of curved bottom portion  62  of shoe  30  includes a scale with markings spaced along top side  82  of shoe  30  adjacent rack  86 . The markings indicate the angle conduit pipe  14  has been bent. During operation of geared conduit bender  10 , whichever marking aligns with angle indicator  150  is the angle that conduit pipe  14  has been bent. The scale allows for the angle to reference something other than the ground. The scale is also relatively close to angle indicator  150  lowering the chances of mistaken angle readings. 
     In the illustrated embodiment, geared conduit bender  10  is capable of bending conduit pipe  14 , such as by up to ninety degrees. Geared conduit bender  10  can be rotated between a starting position ( FIG. 4 ) and a ninety degree bend position ( FIG. 5 ). During operation, geared conduit bender  10  begins in the starting position. In the starting position, first flange  34  of base  22  is flush with the ground or surface leaving a clearance between channel  74  of shoe  30  and the ground. Conduit pipe  14  is inserted into channel  74 , with the intended spot of the bend positioned in hook  78 . To begin bending of conduit pipe  14 , a user engages pin  134  with gear teeth  28  on pinion gear  26 . The user subsequently rotates handle  18  counter-clockwise (as viewed from  FIG. 4 ) and pinion gear  26  about second axis of rotation  54  causes shoe  30  to rotate counter-clockwise, thus bending conduit pipe  14 . In the illustrated embodiment, the rotation of handle  18  is limited to the size of elongated slot  94  in shoe  30 . A full sweep of handle  18  is complete when handle  18  rotates the entire length of elongated slot  94 . 
     Geared conduit bender  10  provides a mechanical force advantage (e.g., as a force multiplier) when applying force to the elongated shaft to bend the elongated workpiece. In the illustrated embodiment, geared conduit bender  10  provides a 3.5 to 1 force reduction. In other words, if a user applies a force of X to handle  18 , a force of 3.5 times X is exerted on conduit pipe  14  by shoe  30 . The force multiplier requires handle  18  to rotate a correspondingly further distance in order to bend conduit pipe  14  to arbitrary angle X (e.g., to an angle of 90 degrees). Handle  18  rotates within elongated slot  94 . In the illustrated embodiment, approximately three sweeps are required to bend conduit pipe  14  ninety degrees. In other embodiments, geared conduit bender  10  can provide a greater or lesser force multipliers requiring greater or fewer sweeps in order to bend conduit pipe  14  to angle X. In other embodiments, the mechanical force advantage provided by geared conduit bender  10  is between a range of 3:1 and 4:1, and in still other embodiments the mechanical force advantage provided by geared conduit bender  10  is between a range of 2:1 and 5:1. 
     As shown in  FIGS. 6 and 7 , pin  134  is disengaged from pinion gear  26  allowing a user to freely rotate handle  18  within elongated slot  94  about first axis of rotation  50 . To disengage pin  134  from pinon gear  26 , a user pulls upward on handle  18 . With pin  134  disengaged, a user can relocate handle  18  within elongated slot  94 . Meanwhile, pinion gear  26  and conduit pipe  14  prevent shoe  30  from rotating while handle  18  is disengaged from pinion gear  26 . To reengage pin  134  to pinion gear  26 , a user pushes handle  18  down so that pin  134  engages on pinion gear  26 , thus allowing the user to complete another sweep. A user can repeat this process until conduit pipe  14  is bent to a desired angle. 
     With reference to  FIGS. 9-11 , reaction arm  158  provides leverage for a user against a surface, such as the floor, when manipulating conduit bender  10 . Reaction arm  158  defines channel  162  in which conduit pipe  14  is placed when being bent. Reaction arm  158  provides a counter-force so that the user may more easily pull handle  18  to bend conduit pipe  14  without the user having to force first flange  34  to the ground. Reaction arm  158  extends from first flange  34  away from hook  78 . In use, as hook  78  pulls conduit pipe  14  while conduit pipe  14  is being bent, hook  78  moves away from reaction arm  158  (best shown  FIG. 10 ). 
     In one embodiment, reaction arm  158  is secured to sidewall  174 , which extends perpendicularly from first flange  34  of base  22 . Reaction arm  158  and sidewall  174  are secured together via a fastener  182  extending through reaction arm  158 , sidewall  174  and securing plate  178 . Bottom surface  166  of reaction arm  158  is generally parallel to and slightly elevated from bottom surface  170  of first flange  34  (best shown in  FIG. 11 ). In various other embodiments, bottom surface  166  of reaction arm  158  is generally coplanar to bottom surface  170  of first flange  34  (not shown). 
     As shown in  FIGS. 9-11 , reaction arm  158  is open-ended such that conduit pipe  14  may be lowered into reaction arm  158 . In other embodiments, not shown, reaction arm  158  is a pipe, and thus conduit pipe  14  is inserted axially into reaction arm  148 . 
     It should be understood that the figures illustrate the exemplary embodiments in detail, and it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for description purposes only and should not be regarded as limiting. 
     Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, logical algorithm, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention. 
     Unless otherwise expressly stated, it is in no way intended that any method set forth herein be construed as requiring that its steps be performed in a specific order. Accordingly, where a method claim does not actually recite an order to be followed by its steps or it is not otherwise specifically stated in the claims or descriptions that the steps are to be limited to a specific order, it is in no way intended that any particular order be inferred. In addition, as used herein, the article “a” is intended to include one or more component or element, and is not intended to be construed as meaning only one. As used herein, “rigidly coupled” refers to two components being coupled in a manner. 
     Various embodiments of the invention relate to any combination of any of the features, and any such combination of features may be claimed in this or future applications. Any of the features, elements or components of any of the exemplary embodiments discussed above may be utilized alone or in combination with any of the features, elements or components of any of the other embodiments discussed above.