Patent Publication Number: US-8534163-B2

Title: Tool for removing sheathing and decking material and the like

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present Application for Patent claims priority benefit of Provisional Application Ser. No. 61/195,682, filed Oct. 9, 2008. This provisional patent application is hereby expressly incorporated by reference herein in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to construction equipment, and more specifically relates to manual, hand-held tools used in the housing industry for removing sheathing, decking and the like from existing structures. 
     2. Background Information 
     For refurbishing existing building structures, very often it is necessary to remove sheathing and decking material from the structure. The sheathing and decking material is usually fastened to and supported by spaced apart joists. 
     Various tools and devices have been provided for removing old sheathing and decking material preparatory to the installation of new replacement sheathing and shingle material. A common method of removing such sheathing and decking material is to use a crowbar or the like. This is a manually exhaustive and time consuming operation. Furthermore, there is very little mechanical advantage in using a crowbar to remove such sheathing and decking material. Such a conventional method may result in muscle strain or even back injury. 
     Other removing tools include generally planar work-engaging heads carried by elongated handles which may be manually manipulated to drive the planar heads beneath sheathing and decking material for the purpose of severing the nails which secure the same to an existing structure. In addition, the handles are supported from the planar heads at an angle whereby the handles may be used as a lever in order to pry shingles from a roof. However, many roofing removing tools of this type are less efficient than desired for various reasons. 
     Accordingly, inasmuch as the removal of sheathing and decking material is a difficult, tiring and dangerous task, a need exists for a sheathing and decking removing tool which will enable a contractor to remove the sheathing and decking material in a more efficient, less tiring and safer manner. 
     The present invention addresses these problems and disadvantages of the conventional method of removing sheathing and decking material in refurbishing a building. 
     SUMMARY OF THE INVENTION 
     It is an object of the present invention is to provide tool for removing sheathing and decking material and the like in an efficient and safe manner. 
     It is another object of the present invention to provide a tool for removing sheathing and decking material and the like with high mechanical advantage so as to allow the removal of such materials from a building construction quickly and easily, and without requiring any excessive force. 
     It is another object of the present invention to provide a tool for removing sheathing and decking material and the like that eliminates any muscle strain or back injury to the user of the tool which may have otherwise resulted from conventional methods and equipment. 
     Still another object of the present invention is to provide a tool for removing sheathing and decking material and the like which may be readily wedged beneath such material and utilized to pry such material for removal thereof from existing building structures. 
     Yet another object of the present invention is to provide a tool for removing sheathing and decking material and the like which is simple in construction, economical to manufacture and easy to use so as to provide a tool that will be economically feasible, long lasting and relatively trouble free in operation. 
     The foregoing and other objects of the present invention are carried out by a tool for removing sheathing and decking material. The tool comprises a generally wedge-shaped head having a rear end and a front end and a handle having a free end portion and a base end portion, the base end portion being integrally connected to the head with the handle free end portion projecting rearwardly from the rear end of the head. The tool further comprises a fulcrum member that removably connects to the head proximate the rear end thereof so that the fulcrum member extends in a direction transverse to the handle to provide a fulcrum during operation of the tool. 
     In an exemplary embodiment, the head comprises a bottom wall, a pair of opposite lateral side walls connected to and extending from opposite edges of the bottom wall, a rear wall disposed at the rear end and connected to the bottom wall and the side walls, a front wall disposed at the front end and connected to and extending between the bottom wall and the side walls, an interior space defined by the bottom, side, rear and front walls, and a support wall disposed in the interior space and extending between and connected to the side walls. The base end portion of the handle is integrally connected to the support wall. 
     According to preferred features of the tool, the support wall is positioned approximately midway between the rear and front walls of the head. The rear wall, the front wall and the support wall are preferably generally parallel to one another. The rear wall has an opening through which the handle extends for connection of the base end portion of the handle to the support wall of the head. Upper edges of the side walls are sloped from the rear wall downwardly towards the front wall. The side walls have a pair of aligned openings proximate the rear end of the head for receiving therethrough the fulcrum member. 
     According to another feature, the tool includes means for preventing relative movement between the fulcrum member and the head. In one embodiment, the means for preventing relative movement comprises a pair of depressible protrusions mounted on the fulcrum member for engagement with the respective side walls. 
     As another feature, the toll includes means for adjusting the position of the fulcrum member to preselected positions relative to the head in the direction transverse to the handle. In one embodiment, the means for adjusting comprises the pair of aligned openings that permit movement of the fulcrum member relative to the head in the direction transverse to the handle and a pair of depressible protrusions mounted on the fulcrum member for engagement with the side walls of the head to removably connect the fulcrum member to the head at any one of the preselected positions. 
     As yet another feature, the tool includes storage means for storing the fulcrum member during non-use of the tool. In one embodiment, the storage means comprises a bore of the tubular handle having an inner diameter greater than an outer diameter of the fulcrum member for receiving therein the fulcrum member, the handle having a hole communicating an exterior surface of the tubular handle with the bore thereof such that when the fulcrum member is inserted into the bore of the tubular handle, one of the depressible protrusions of the fulcrum member engages the hole of the tubular handle to removably retain and store the fulcrum member in the bore of the tubular handle. 
     In yet another embodiment, the handle comprises an elongated tubular member, and a weight body is disposed in the tubular member at a regions thereof including a portion of the tubular member extending through the opening of the rear wall of the head and the free end portion position of the tubular member connected to the support wall. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing summary, as well as the following detailed description of the preferred embodiments of the invention, will be better understood when read in conjunction with the accompanying drawings. For the purpose of illustrating the invention, there is shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangement and instrumentalities shown. In the drawings: 
         FIG. 1  is a perspective view of the tool for sheathing and decking material and the like in accordance with the present invention illustrating the orientation of the tool during use; 
         FIG. 2  is another perspective view of the tool in accordance with the present invention, with the depressible protrusions of the fulcrum member omitted for simplicity of explanation only; 
         FIG. 3  is a top plan view of the tool in accordance with the present invention; 
         FIG. 4  is a side elevational view of the tool in accordance with the present invention; 
         FIG. 5  is a front elevational view of the sheathing and decking remover in accordance with the present invention; 
         FIG. 6  is a side view of the fulcrum member of the tool in accordance with the present invention; and 
         FIG. 7  is a top plan view showing modified embodiments of the tool in accordance with the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     While this invention is susceptible of embodiments in many different forms, this specification and the accompanying drawings disclose only presently preferred embodiments of the invention. The invention is not intended to be limited to the embodiments so described, and the scope of the invention will be pointed out in the appended claims. 
     Certain terminology is used in the following description for convenience only and is not intended to be limiting. The words right, left, front, top, rear, back, upper, lower, inner, outer, rearwardly and forwardly designate directions in the drawing to which reference is made. Such terminology includes the words above specifically mentioned and words of similar import. 
     In the following description of the preferred embodiments of the present invention, the term “about” is used to quantify the preferred dimensions and weights of the tool and its components. The term “about” is defined to cover the specific dimensions and weights described as well as values within a range of ±10% of the specific dimensions and weights described. 
     The preferred embodiments of the tool according to the present invention is described below with a specific application to removing sheathing and decking material and the like. However, it will be appreciated by those of ordinary skill in the art that the remover of the present invention is also specifically well adapted for removal of other related or different types of flooring materials and roof covering materials (e.g., shingles, felt, tar paper), for example. 
     Referring now to the drawings in detail, wherein like numerals are used to indicate like elements throughout, there is shown in  FIGS. 1-7  exemplary embodiments of a tool for removing sheathing and decking material and the like (hereinafter “remover”), generally designated at  10 , according to the present invention. The remover  10  includes a head or pry box  12  having a side wall opening (first opening)  12   a , a pair of aligned side wall openings (second openings)  12   b  and an upstanding reinforcing support wall  13 , a fulcrum member in the form of a crossbar  14  configured for passing through the pair of side wall openings  12   b  of the pry box  12  for providing a fulcrum during use of the remover  10 , and an elongated handle  16  passing through the side wall opening  12   a  of the pry box  12  and affixed at an axial end (base end portion) thereof to the support wall  13  so as to be generally transverse to the crossbar  14 . In the exemplary embodiment, the handle  16  is generally perpendicular to the crossbar  14 . However, it will be appreciated that other angular relationships are suitable between the crossbar  14  and the handle  16  without departing from the spirit and scope of the present invention. 
     The pry box  12  includes a front end, a rear end, a top end and a bottom end opposite the top end. The bottom end is closed by a bottom wall having a plurality of side walls defining an open, generally wedge-shaped box structure that is open at the top end of the pry box  12  to provide a cavity or interior space  18 . More specifically, the pry box  12  includes a bottom wall  20 , a pair of opposite lateral side walls  22  (left and right side walls as viewed in  FIG. 2 ) connected or joined to and extending from opposite edges of the bottom wall  20 , a rear or back wall  24  at the rear end joined to the bottom wall  18  and the lateral side walls  22 , and a short front wall  26  at the front end defining a narrow shovel nose, which also extends between the bottom wall  18  and the lateral side walls  22  and which is positioned opposite the back wall  24 . 
     Referring to  FIGS. 1 ,  2 ,  4  and  5 , the back wall  24  is greater in height than the front wall  26  so that upper or top edges  22   a  of the side walls  22  are sloped from the back wall  24  downwardly towards the front wall  26  to provide the pry box  2  with its wedge shape. Situated within the cavity or interior space  18  of the pry box  12  is the upstanding support wall  13  which extends between the side walls  22  and which is preferably parallel with the back wall  24  and the front wall  26 . The support wall  13  is preferably positioned about midway between the back wall  24  and the front wall  26 , and provides strength to the pry box  2  with minimal additional weight. The support wall  13  is integrally secured to the bottom wall  20  and the side walls  22 , such as by weld  28 . It is understood, however, that other forms of integral connection between the support wall  13  and the bottom wall  20  are suitable, including various types of fasteners. 
     As best shown in  FIGS. 2 and 4 , the side wall openings  12   b  of the pry box  12  are formed through the thickness of the opposite side walls  22  and are preferably situated near or at the juncture between the side walls  22  and the back wall  24 . The side wall openings  12   b  are provided in the side walls  22  to removably receive the crossbar  14  which, as shown in  FIGS. 1-4 , is passed through the side wall openings  12   b  and the cavity or interior space  18  of the pry box  12  to act as a fulcrum during operation of the remover as further described below. The crossbar  14  is preferably hollow and tubular in form to minimize the overall weight of the sheathing and decking remover  10 , and yet is formed with a diameter and thickness which are sufficient to provide the remover with the required strength for removing sheathing and decking material from a building structure. In the exemplary embodiment, the side wall openings  12   b  of the pry box  12  are generally circular-shaped to receive therethrough the tubular crossbar  14  of similar circular-shaped cross-section. It will be appreciated, however, that other shapes and cross-sections are suitable for the side wall openings  12   b  and the tubular crossbar  14 , such as oval, rectangular, triangular, hexagon, octagon, or other suitable shapes and cross-sections. 
     Referring to  FIG. 6 , the tubular crossbar  14  preferably includes spring loaded depressible protrusions  30   a ,  30   b  selectively projecting from the outer surface of the crossbar  14  and formed through the thickness of the crossbar and spaced apart from one another a predetermined distance which may be slightly greater than or slightly less than the width of the wedge-shaped pry box  12  so that, when the crossbar  14  is inserted into the side wall openings  12   b  of the pry box  12 , the depressible protrusions  30   a ,  30   b  engage the respective side walls  22  to prevent relative lateral or transverse movement of the crossbar  14  relative to the pry box  12 , as shown in  FIGS. 1 and 2  (in  FIG. 2  the depressible protrusions  30   a ,  30   b  have been omitted for simplicity of explanation only). Thus the depressible protrusions  30   a ,  30   b  define means for preventing movement of the crossbar  14  in the direction generally transverse to the handle  16 . It will be appreciated by those skilled in the art that the means for preventing movement is not limited to spring loaded depressible protrusions. For example, cotter pins of high grade material extending through-holes formed in the crossbar  14  for engagement with the side walls  22  of the pry box  12  are also suitable for preventing movement of the crossbar  14  in the direction generally transverse to the handle  16 . 
     The position of the crossbar  14  shown in  FIGS. 1 and 2  is a first position of the crossbar  14  relative to the pry box  12 . Another function of the depressible protrusions  30   a ,  30   b  is to permit adjustment of the position of the crossbar  14  in two additional positions (e.g., second and third positions, not shown) relative to the pry box  12  by displacing or moving the crossbar in left and right directions relative to the handle  16 , as denoted by arrows X and Y, respectively, in  FIGS. 1 and 2 . For example, the second position of the crossbar  14  relative to the pry box  12  is achieved by depressing the protrusion  30   b  and displacing the crossbar  14  in the direction of arrow X until the protrusion  30   a  abuts the inner surface of the left side wall  22 . The third position of the crossbar  14  relative to the pry box  12  is achieved by depressing the protrusion  30   a  and displacing the crossbar  14  in the direction of arrow Y until the protrusion  30   b  abuts the inner surface of the right side wall  22 . In the second and third positions of the crossbar  14  relative to the pry box  12 , the utility of the remover  10  is increased by permitting the remover to remove sheathing and decking materials from areas of a deck or sheathing which are difficult to reach (e.g., corners and/or other confined areas) in the first position of the crossbar  14  relative to the pry box  12 , as shown in  FIG. 1-2 . Thus, the depressible protrusions  30   a ,  30   b  of the crossbar  14  and the side wall openings  12   b  of the side walls  22  define adjusting means for adjusting a position of the crossbar  14  in directions generally transverse to the handle  16  (i.e., in directions along a length or longitudinal axis of the crossbar  14 ). It will be appreciated by those skilled in the art, that in each of the foregoing first, second and third positions of the crossbar  14 , the construction and positional relationship of the components allow for ergonomic positioning of the handle  16  and the crossbar  14  to achieve the required fulcrum during use of the remover  10 . 
     The side wall opening  12   a  is formed through the thickness of the back wall  24  of the pry box  12 . The elongated handle  16  passes through the side wall opening  12   a  and is affixed at the axial end thereof to the support wall  13  such as by welding or other integral form of connection, such by removable fasteners. The support wall  13  has an opening  13   a  that receives the axial end of the handle  16  which is secured thereto by welding, for example. The elongated handle  16  is preferably hollow and tubular in form to minimize the overall weight of the sheathing and decking remover  10 , and yet is formed with a diameter and thickness which are sufficient to provide the remover with the required strength during removal of sheathing and decking material from a building structure. In the exemplary embodiment, the side wall opening  12   a  of the pry box  12  is generally circular-shaped to receive therethrough the tubular handle  16  of similar circular-shaped cross-section. It will be appreciated, however, that other shapes and cross-sections are suitable for the side wall opening  12   a  and the tubular handle  16 , as described above for the side wall openings  12   b  and the tubular crossbar  14 . 
     The tubular handle  16  is relatively long, that is, preferably on the order of six or seven feet, for example, to provide maximum mechanical advantage for the user of the sheathing and decking remover  10 , yet not so long that the remover becomes unwieldy to handle or cumbersome to store. Preferably, as shown in  FIG. 7 , the outer diameter of the tubular crossbar  14  is less than the inner diameter of the tubular handle  16  so that, when the remover  10  is not being used, the crossbar  14  may be removed therefrom and stored within the bore of the tubular handle  16 , thereby reducing the overall width of the sheathing and decking remover  10  and increasing the storage capability of the remover  10 . In the stored configuration, the crossbar  14  is supported within the bore of the tubular handle  16  by engagement between one of the depressible protrusions  30   a ,  30   b  with an opening  16   a  of the tubular handle  16 , with a portion  14   a  of the crossbar  14  extending from an axial free end (free end portion) of the tubular handle  16 . In  FIG. 7 , the depressible protrusion  30   b  engages the opening  16   a  of the tubular handle  16 . The crossbar  14  is removed from the bore of the tubular handle  16  by depressing the depressible protrusion  30   b  and pulling the crossbar  14  outwardly from the portion  14   a  of the crossbar  14 . Thus the bore of the handle  16  and the engagement between the depressible protrusion  30   a  or  30   b  of the crossbar  14  and the opening  16   a  of the handle  16  define means for storing the crossbar  14  during non-use of the remover  10 . By this construction and corresponding functions, the present invention provides a remover that can be stored in the bore of the handle and which is readily accessible and movable from a storage position, during non-use of the remover, to a fulcrum generating or action position ready for performing a removal operation as further described below. 
       FIG. 7  shows another exemplary embodiment of the sheathing and decking remover  10  according to the present invention. In this exemplary embodiment, a weight member  32  is inserted into the bore of the tubular handle  16  so as to extend to the axial end thereof that is affixed to the support wall  24  of the pry box  12 . The weight body or member  32  is preferably retained within the bore of the tubular handle  16  by friction fit, or other equivalent manner, and may be solid or tubular in construction. The purpose of the weight member  32  is to add weight to the remover  10  at the area of intersection between the tubular handle  16  and the pry box  12  in order to increase the mechanical advantage during use of the remover  10  to enable a removal operation without requiring any excessive force. Preferably, the overall weight of the remover  10  is in the range of about 13 pounds to about 17 pounds, and more preferably about 15 pounds, with the weight member  32  preferably representing from about 1 pound to about 3 pounds, and more preferably 3 pounds, of the overall weight of the remover  10 . 
       FIGS. 6-7  show preferred dimensions for the pry box  12 , the crossbar  14  and the handle  16 . The overall width or outer lateral dimension a of the pry box  12  is selected so that it may fit between the space provided between adjacent joists in most residential and commercial constructions. Oftentimes, joists are spaced apart twelve, sixteen or twenty-four inches on center. Therefore, the preferred outer lateral dimension of the pry box  12  of the remover  10  is preferably in the range of about 8.75 inches to 10.75 inches, and more preferably about 9.75 inches. The length b of the pry box  12  is selected in proportion to the overall width a, and is preferably in the range of about 15 inches to 17 inches, and more preferably about 16 inches. Similar concerns are taken into account when choosing the length of the tubular crossbar  14 , so that the crossbar  14  may rest on at least two adjacent joists, or more joists during use. Preferably, the length c of the crossbar  14  is in the range of about 39 inches to about 41 inches, and more preferably about 40 inches. The length d of the handle  16  is selected in proportion to the foregoing selected dimensions a, b and c, and is preferably in the range of about 71 inches to 73 inches, and more preferably about 72 inches. The length of the weight member  32  is preferably in the range of about 23 inches to 25 inches, and more preferably 24 inches. 
     The pry box  12  is formed of sheet metal or the like and is preferably hollow to decrease the weight thereof. The sheet metal forming the pry box  12  may be formed from aluminum, such as light weight aircraft aluminum, or other material. When formed from aluminum, the pry box  12  is preferably about 0.25 inches in thickness to provide sufficient rigidity and strength to the pry box  12 . 
     Preferably, the tubular crossbar  14  is formed of a high grade steel and the tubular handle  16  and weight member  32  are formed of aluminum. It understood, however, that other materials are suitable for the tubular crossbar  14 , tubular handle  16  and weight member  32 , including but not limited to titanium, and alloys of steel, aluminum and titanium. 
     During an operation of the remover  10  to remove sheathing, decking or the like from a building construction, the handle  16  is manipulated by an operator to position the remover  10  such that the wedge-shaped pry box  12 , in the orientation shown in  FIG. 1 , is situated between adjacent joists supporting the deck or sheathing with the crossbar  14  being oriented perpendicularly to the running direction of the joints and resting on the surface of the joists which support the sheathing or decking. The front wall  26  (i.e., the narrow shovel nose) of the wedge-shaped pry box  12  is inserted at an angle underneath the sheathing or decking to be removed, with the handle  16  being disposed in a raised, angular position with respect to the plane in which the decking or sheathing resides. The operator then pushes down on the axial free end of the handle  16  opposite the wedge-shaped pry box  12  to cause the pry box  12  to pivot upwardly against the bottom of the sheathing or decking attached to the joists, with the crossbar  14  acting as a fulcrum. The wedge-shaped box  12  forces the sheathing or decking to lift off the supporting joists on which it is attached. The remover  10  is then advanced on the spaced apart joists to the next adjacent sheathing or decking, and the lifting operation is repeated. Preferably, the remover is then repositioned between the next adjacent pair of joists and the operation is repeated until all of the sheathing or decking has been removed. 
     The remover of the present invention, because of the mechanical advantage it provides and its construction, removes sheathing and decking and like materials from a building construction quickly and easily, and without requiring any excessive force. In particular, by providing the pry box with a front wall forming a narrow shovel nose, the remover can effectively be inserted into tight and narrow spots requiring removal of sheathing and decking material and the like. Thus, the sheathing and decking remover of the present invention minimizes or eliminates any muscle strain or back injury to the user of the remover which may have otherwise resulted from conventional methods and equipment. Removal of sheathing and decking material and the like using the remover of the present invention requires less time and lowers construction costs as compared to the conventional methods and equipment. 
     While the present invention has been described in terms of specific embodiments, it is to be understood that the invention is not limited to these disclosed embodiments. This invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided by way of illustration only and so that this disclosure will be thorough, complete and will fully convey the full scope of the invention to those skilled in the art. Indeed, many modifications and other embodiments of the invention will come to mind of those skilled in the art to which this invention pertains, and which are intended to be and are covered by both this disclosure, the drawings and the claims.