Patent Publication Number: US-2013248784-A1

Title: Accessory Kit Apparatus and Method For One or More Heavy-Duty Floor Jack

Description:
BACKGROUND OF THE INVENTION 
     This invention relates generally to methods and apparatus for removing a drive shaft (or differential), and more particularly to methods and apparatus for removing a drive shaft of a heavy vehicle, such as a semi-trailer truck (a “semi” or “18 wheeler”), using an accessory kit and two or more heavy-duty floor jacks, and to a floor jack suitable for such removal. 
     Lowering a drive shaft to remove a transmission under a semi can be a difficult task when performed by a floor jack, especially when the vehicle is heavy and no special apparatus is available to center the two drive shafts (“differentials”) on a supporting member of the jack. In at least some known embodiments of jacks, a special apparatus is required to hold a differential or transmission on the jack while the axle is lowered to prevent the vehicle from tilting dangerously to one side or the other. Many known differentials weigh approximately 200 pounds (about 90 kilograms) each. Thus, at least two people are required when lowering the differential. Moreover, the middle portion (carrier bearing) of the differential moves, tending to make the drive shafts slope down. 
     It would be thus desirable if a simple, portable, and adaptable apparatus existed for such lowering and removing of a drive shaft or differential. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one aspect, some configurations of the present invention therefore provide an accessory kit apparatus for use with heavy-duty floor jacks. The accessory kit includes at least one extension tube with a first end configured to engage a matching mounting area of a lowering member of the floor jack and a second end. The accessory kit also includes a separable top support member having a mounting portion extending from a flat base, the mounting portion configured to engage the second end of the extension tube. The separable top support member also has a channel member and a hinge, whereby the channel member is hinged to an edge of the flat base, the channel member having rims defining a channel. The flat base supports the flat base is configured to support the channel member when the jack is in use. 
     In another aspect, some configurations of the present invention provide a lowering apparatus having a floor jack and at least one extension tube with a first end configured to engage a matching mounting area of a lowering member of the floor jack and a second end. These configurations also include a separable top support member having a mounting portion extending from a flat base. The mounting portion is configured to engage the second end of the extension tube. The mounting portion also has a channel member and a hinge, whereby the channel member is hinged to an edge of the flat base. The channel member has rims defining a channel, and the flat base is configured to support the channel member when the lowering apparatus is in use. 
     In still another aspect of the present invention, a method for lowering a drive shaft of a vehicle is provided. The method includes placing opposite sides of the drive shaft in channels of two lowering apparatus, one lowering apparatus supporting each side of the drive shaft, and each lowering apparatus having a hinged channel member. The method further includes using one of the lowering apparatus to lower a first of the sides of the drive shaft it is supporting, while allowing the channel member of each lowering apparatus to tilt as the first side of the drive shaft is lowered. The method also includes using the other lowering apparatus to lower the second of the sides of the drive shaft it is supporting, while allowing the channel member of each lowering apparatus to tilt as the second side of the drive shaft is lowered. 
     It will be appreciated that various configurations of the present invention provide one or more advantage over known methods and apparatus for lowering a drive shaft. Namely, the various configurations of the present invention provide simple means and/or methods for lowering the drive shaft by one person using a lowering apparatus. The drive shaft can be held in place while it is tilted, and the apparatus can be simple, portable, and/or adaptable to various vehicles, or any combination thereof. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a drawing of an embodiment of an accessory kit and a prior art heavy-duty floor jack, with a portion of the accessory kit mounted on the heavy-duty floor jack and ready for use. 
         FIG. 2  is a drawing of a prior art floor jack suitable for use with the accessory kit embodiment shown in  FIG. 1 , but shown without an accessory kit in  FIG. 2 . 
         FIG. 3  is a drawing showing the insertion of an accessory kit extension tube into a lowering member of the floor jack. 
         FIG. 4  is a drawing of a top support member shown in  FIG. 1 , but shown unassembled and upside down to illustrate certain details of the top support member. 
         FIG. 5  is a drawing of an assembly suitable for lowering a drive shaft, wherein the assembly comprises a portion of the accessory kit of  FIG. 1  and the prior art floor jack of  FIG. 2 . 
         FIG. 6  is a drawing of an assembly similar to that of  FIG. 5  except that a chain shown in  FIG. 5  is shown in a securing configuration and the channel member shown in  FIG. 5  is shown hinged from a horizontal position. In addition, ribs on an extension tube are also shown. 
         FIG. 7  is a drawing showing how a pair of extension tubes can be used with a joining member to create an assembly that can be used to mount a top support member at a height greater than that possible using only a single extension tube. 
         FIG. 8  is a drawing showing supporting ribs of an extension tube. 
         FIG. 9  is a drawing showing a pair of lowering apparatus supporting a portion of a drive shaft in a tilted, non-horizontal position, as would occur during a portion of the time a drive shaft of the vehicle is lowered during performance of some method embodiments of the present invention. 
     
    
    
     The foregoing summary, as well as the following detailed description of certain embodiments of the present invention, will be better understood when read in conjunction with the appended drawings. 
     DETAILED DESCRIPTION OF THE INVENTION 
     As used herein, an element or step recited in the singular and proceeded with the word “a” or “an” should be understood as not excluding plural said elements or steps, unless such exclusion is explicitly stated. Furthermore, references to “one embodiment” of the present invention are not intended to be interpreted as excluding the existence of additional embodiments that also incorporate the recited features. Moreover, unless explicitly stated to the contrary, embodiments “comprising” or “having” an element or a plurality of elements having a particular property may include additional such elements not having that property. 
     Referring now to  FIG. 1  and  FIG. 2 , some embodiments of the present invention provide an accessory kit apparatus  10  for use with (or including), e.g., a prior art floor jack  12  (e.g., a heavy-duty floor jack  12  of a type that may be originally intended to raise a vehicle by an axle). The kit  10  includes one or more extension tubes  14  that are configured to engage a matching mounting area  16  of a lowering member  18  of the floor jack  12 . For example, in some embodiments and referring to  FIG. 3 , the one or more extension tubes  14  have threads  13  so that they can be screwed firmly into a matching threaded hole  16  in the lowering member  18 . Referring to  FIG. 1  and  FIG. 4 , the accessory kit  10  also includes a separable top support member  20 . The top support member  20  includes a mounting portion  22  extending from its base  24 , which may be a flat base. The mounting portion  22  is configured to engage an end  11  of an extension tube  14  opposite an end  17  engaged with the lowering member  18 . For example, in some embodiments, the extension tube  14  is essentially cylindrical and the mounting portion  22  is a rod-like portion extending at right angles from the bottom of the base  24  and dimensioned to fit within the cylindrical hole at end  11  of the extension tube  14 . 
     In addition to its base  24  and referring now to  FIG. 5 , the top support member  20  further includes a channel member  26  having upwardly extending rims  28  that define a channel  36  in which an axle (not shown in  FIG. 5 , but, e.g., an axle of a heavy vehicle) can be supported. The channel member  26  is itself hinged via a hinge  27  to an edge  30  of the base  24 . In some embodiments, the rims  28  of the channel member  26  are on edges of channel member  26  that are at right angles to the hinged edge  29  of channel member  26 . The base  24  supports the channel member  26  when the floor jack  12  is in use and when the accessory kit  10  is used. When the drive shaft is horizontal, the channel member  26  itself is also horizontal, and the base  24  is fully supported by the channel member  26 . When the drive shaft is at an angle to horizontal, the channel member  26  tilts accordingly relative to base  24 , and is supported by the base  24  via at least the hinge  27 . An illustration of a tilted channel member  26  is shown in  FIG. 6 , although the amount of tilting in actual use may be somewhat less than in many instances than is illustrated. 
     In some embodiments, the separable top support member  20  further includes an attached securing member  34  (for example, an attached chain) that is configured to hold a drive shaft in place within the channel  36  of the channel member  26 . For example and referring to  FIG. 1  and  FIG. 5 , the attached securing member  34  or chain can be wrapped over the top of the rims  28  of the channel member  26  and over the drive shaft in the channel  36  when the drive shaft (not shown in  FIG. 1  or in  FIG. 5 ) is in the channel  36 . If a chain is used as securing member  34 , for example, the chain can be tightened around the drive shaft and channel member  26  using a tightening mechanism  32  such as a bolt, wing nut, and/or lock. 
     In some embodiments and referring again to  FIG. 1 , to allow a greater range of operability, a plurality of extension tubes  14  of differing length are provided in an extension kit  10 . Some embodiments also provide one or more joining members  15  that is/are suitably configured to connect two extension tubes  14  to provide an even greater range of operating lengths. For example, extension tubes  14  are cylindrical in some configurations. In other configurations, extension tubes  14  have longitudinal ribs or are otherwise shaped or configured to reduce or eliminate the likelihood of extension tubes  14  from rolling away so that a person under a truck assembling the extension kit need not worry about getting up to fetch an extension tube  14  that has rolled out of reach. A joining member  15  comprising a rod or cylinder having opposite ends  38 ,  40  and a circumferential rib  42  between the opposite ends  38 ,  40  is also provided. The circumferential rib  42  is of sufficient diameter to support the joining member  15  at the height of the circumferential rib  42  at the end  11  (see  FIG. 3 ) of an extension tube  14 , In some embodiments and referring also to  FIG. 7 , the circumferential rib  42  is located on the joining member  15  in a position such that one of the ends  38  of the joining member  15  can be inserted in one extension tube  14  and the other end  40  of the joining member  15  is available to insert in a second extension tube  14 . This embodiment allows the separable top support member  20  to be supported at at least three different heights instead of two without having to provide an extension tube  14  representing the greatest height. In embodiments with more than two extension tubes  14 , or in embodiments in which circumferential rib  42  is not located equidistant from opposite ends  38  and  40 , an even greater variety of heights can be made available. 
     In some embodiments and referring to  FIG. 6  and  FIG. 8 , all or some of the extension tubes  14  themselves can be reinforced to strengthen them and to allow them to support greater weights than would be possible without reinforcement. Also, in some embodiments, extension tubes  14  can have longitudinal ridges or ribs  44  to help prevent extension tubes  14  from rolling away if dropped. Thus, a mechanic would not have to get out from under the semi to retrieve a dropped tube that rolls across the floor. 
     Some configurations of the present invention provide two accessory kits to fit on two floor jacks, as many uses of the accessory kit will be in conjunction with the use of jacks on both sides of a differential of a heavy vehicle. Still other configurations include both the accessory kit and one or more floor jacks in combination. In general, kits may be marketed with enough accessory parts for one floor jack, or for more than one floor jack, and the kits may be marketed with or without one or more floor jacks, to allow unequipped or partially equipped shops flexibility in purchasing kits for their specific needs or as replacement parts if needed. 
     In some embodiments and referring to  FIG. 9 , a method for lowering a drive shaft  46  of a vehicle (represented by left side front wheel  66  and driven left side rear wheel  64 ) is provided. This method includes placing opposite sides  48 ,  50  of the drive shaft  46  (separated by bearing assembly  56  and universal joint  62  in the illustrated configuration) in the channels  36  of two lowering apparatus  52 ,  54 , one supporting each side of drive shaft  46 . (Lowering apparatus  52  and  54  are shown only in part, and not necessarily to scale. The wheels of lowering apparatus  52  and  54  would, in most configurations, be on a level floor, as would left side front wheel  66  and driven left side rear wheel  64 .) By “opposite sides,” it is meant, for example, that one lowering apparatus  52  lowers a side  48  of the drive shaft  46  between bearing assembly  56  and universal joint  62  and a differential  60 , while the other lowering apparatus  54  lowers a side  50  of the drive shaft  46  between a transmission  58  and the bearing assembly  56  and the universal joint  62 . Thus, sides  48 ,  50  of the drive shaft  46  are on opposite sides of the bearing assembly  56  and the universal joint  62 . Each lowering apparatus  52 ,  54  has a hinged channel member  26  supporting a corresponding portion  48 ,  50  of drive shaft  46 . Drive shaft  46  is separated from transmission  58  and differential  60 . A first lowering apparatus  52  of the two lowering apparatus  52 ,  54  is then used (e.g., pumped down) to lower the side  48  of the drive shaft  46  it is supporting. In the process of lowering the drive shaft, the drive shaft  46  will tilt away from the horizontal, as in  FIG. 9 , but the channel member  26  of each lowering apparatus is hinged. Thus, the channel member  26  of each lowering apparatus  52 ,  54  is allowed to tilt as the first side  48  of the drive shaft  46  is lowered. The other lowering apparatus  54  is then used to lower the side  50  of the drive shaft  46  it is supporting. The lowering of the drive shaft  46  by the other lowering apparatus  54  will also cause the drive shaft  46  to tilt, this time towards the horizontal (or to, or even past horizontal). The channel members  26  of each of the lowering apparatus  52 ,  54  are allowed to tilt during this phase of lowering as well. In this manner, the drive shaft  46  can be quickly and efficiently lowered without the use of heavier and/or more expensive, heavy, or exotic lowering machines. 
     In some embodiments of the present invention, the drive shaft  46  is secured to each hinged channel member  26 , for example, by tightening securing members  34  such as chains around the drive shaft  46  while it is resting in the channels  36  of each channel member  26 . Also in some embodiments of the present invention, a height of a top support member  20  above the ground is selected by engaging an extension tube  14 , or a combination of extension tubes  14  and/or joining members  15  (not shown in  FIG. 9 , but shown in  FIG. 7 ) with a lowering member  18  of each floor jack  12 , and placing a separable top support member  20  at the top of the extension tube  14  or combination of extension tubes  14  and/or joining members  15  (not shown in  FIG. 9  but shown in  FIG. 7 ). 
     To summarize, an accessory kit for a heavy-duty floor jack is advantageously provided in some embodiments of the present invention. The accessory kit includes at least one threaded extension tube configured to mount in a matching threaded hole in a lowering member of the floor jack. In some embodiments, a plurality of extension tubes are provided that may be mounted individually or in combination to achieve a desired height for a separable top support member. The separable top support member includes a mounting portion extending from a flat base, wherein when the jack is in use, the mounting portion fits within or around an extension tube mounted in the hole in the lowering member of the floor jack. A channel member is hinged to an edge of the flat base. The channel member has upwardly extending rims on edges at right angles to the hinged edge. The flat base supports the channel member when the jack is in use. Two such jacks with accessories can support a drive shaft on each side. Because the jacks will not necessarily be at equal height, the drive shaft may be tilted at times. When the drive shaft is tilted, the hinge moves in response thereto to allow the jack to better support the drive shaft than would be the case if there were no hinge and the drive shaft were supported by a member level to the ground. A chain attached to the top support member is provided that can be used to hold the drive shaft in place in the channel. 
     While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.