Patent Publication Number: US-10322441-B2

Title: Hand tool for bending rebar

Description:
TECHNICAL FIELD 
     The present invention relates to tools used to bend rebar and other long and slender objects. 
     BACKGROUND OF THE INVENTION 
     Rebar (short for reinforcing bar) is a steel bar used to reinforce concrete and masonry structures. Rebar&#39;s surface is often patterned to form a better bond with the concrete. Straight lengths of rebar must often be bent into desired shapes at a shop or project site. 
     A hand tool known as a “Hickey bar” or “Hickey” is commonly used by construction tradesmen to manually bend rebar. Hickeys have a tool head for engaging the rebar and a long handle for applying force necessary to make the bend. The tool head and handle are typically rigidly connected. The handle is long to provide a long lever arm so that greater bending moments (or torque) can be achieved with manual strength. 
     “Bending moment” and “torque” may be used interchangeably herein to indicate static or dynamic rotational forces at the tool head created by manually applied forces on the Hickey handle. The term “axis” with respect to bending moment or torque refers generally to the torque axis, whether it is static or dynamic. The axis of rotation of a Hickey bar or tool head is considered herein to be coincident with the torque axis for purposes of describing the invention. The bend of the rebar will generally be in a plane that is perpendicular to the torque axis. The term “bend axis” may be used to characterize the axis of a bend radius, which bend axis is considered herein to be parallel to the torque axis. 
     A typical pin type of Hickey is shown  FIGS. 5 a  and 5 b   , the tool head of which typically has three pins. The straight rebar is placed in the space between the pins, with one pin on one side of the rebar and two pins on the other side. A three-pin Hickey provides three placement options, so that the Hickey handle may be oriented in one of three orientations relative to the rebar. 
     Another popular type of Hickey is shown in  FIGS. 6 a  and 6 b   , which has a U-shaped tool head for engaging the rebar and which provides only one possible orientation of the handle to the rebar. 
     There is a need for a Hickey that provides a greater range of possible handle orientations so that tradesmen can position the Hickey handle in more advantageous orientations, so as to provide improved ergonomics, better leverage, less injury, and improved access to and maneuverability in tight spaces. There is a need for a Hickey that allows adjustment of the handle orientation without disengagement of the tool head from the rebar, so that a bend can be made in increments and the handle can be optimally positioned for each increment according to the preferences of the tradesman or according to other parameters such as workspace restrictions. 
     The present invention fills those and other needs. 
     SUMMARY OF THE INVENTION 
     In a first aspect, the present invention provides a hand tool for bending rebar, comprising: a ratchet mechanism; a handle extending from the ratchet mechanism; and a hickey tool head connected to the ratchet mechanism. The tool head comprises at least one engagement surface for engaging rebar. The at least one surface forms a space for receiving the rebar. 
     In a second aspect, the present invention provides a tool head for a rebar bending tool, comprising: a base adapted for attachment to a drive; and at least one engagement surface for engaging rebar and transmitting torque to the rebar. The at least one surface forms a transverse space for receiving the rebar in a transverse orientation to the torque axis. 
     In a third aspect, the present invention provides a tool for bending rebar, comprising: a base adapted for attachment to a driving device; a plurality of spaced apart extensions extending from the base so as to form a plurality of transverse spaces for receiving rebar; a ratchet mechanism releasably attachable to the base; and a handle attached to the ratchet device. The plurality of spaces comprise a first space having a first width to fit over rebar of a first standard rebar diameter and second space having a second width to fit over rebar of a second standard rebar diameter. 
     In a fourth aspect, the present invention provides a method of manufacturing a hickey bar tool head, comprising the steps of: machining into a block at least one transverse channel for receiving a rebar; and machining into the same block surfaces for engagement with a drive mechanism. 
     In a fifth aspect, the present invention provides method of bending rebar, comprising the steps of: engaging a ratcheting hickey bar with the rebar; applying torque to the hickey bar in the locked direction of the ratchet wherein the rebar bends as the hickey bar handle and the head rotate from a first position to a second position in response to the torque 
     In a sixth aspect, the present invention provides a tool kit comprising at least one Hickey bar tool head and at least one ratchet mechanism compatible for connection with at least one of the at least one tool head. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The subject matter that is regarded as the invention is particularly pointed out and distinctly claimed in the concluding portion of the specification. The invention, however, may be best understood by reference to the following detailed description of various embodiments and the accompanying drawings in which: 
         FIG. 1  is a perspective view of one embodiment of a Hickey bar in accordance with the present invention, with only part of the handle length showing; 
         FIG. 2 a    is a side view of the Hickey bar of  FIG. 1  with the handle length shown in broken view; 
         FIG. 2 b    is a top view of the Hickey bar of  FIG. 2   a;    
         FIG. 2 c    is a bottom view of the Hickey bar of  FIG. 2   a;    
         FIG. 2 d    is an end view of the Hickey bar of  FIG. 2   a;    
         FIG. 2 e    is a perspective view of an embodiment of a ratchet mechanism that may be utilized in an embodiment of the present invention. 
         FIG. 3 a    is a perspective view of the tool head of the Hickey bar of  FIG. 1 ; 
         FIG. 3 b    is a side view of the tool head of  FIG. 3   a;    
         FIG. 3 c    is a top view of the tool head of  FIG. 3   b;    
         FIG. 4 a    is a perspective view of a Hickey bar of the present invention in operation bending a piece of rebar; 
         FIG. 4 b    is an enlarged view of the portion of  FIG. 4 a    identified by line A-A in  FIG. 4   a;    
         FIG. 5 a    is a perspective view of a type of Hickey bar of the prior art; 
         FIG. 5 b    is an enlarged view of the portion of  FIG. 5 a    identified by line A-A in  FIG. 5   a;    
         FIG. 6 a    is a perspective view of another type of Hickey bar of the prior art; 
         FIG. 6 b    is an enlarged view of the portion of  FIG. 6 a    identified by line A-A in  FIG. 6   a.    
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference to  FIGS. 1 and 2   a - 2   d , a preferred embodiment of the present invention comprises handle  10  attached to ratchet mechanism  20  attached to tool head  30 . The ratchet mechanism, like those typical of many commercially available ratcheting socket wrenches, has operational modes in which the drive is locked relative to the handle in one rotational direction and free to turn relative to the handle in the opposite direction. The operational modes can be easily switched from one direction to the other. In the embodiment of  FIG. 2 a -2 d   , a switch lever  21  is provided to change the ratchet mode between locked-clockwise and locked-counterclockwise. Other ratchet modes may include locked in both directions and free in both directions. The Hickey bar and rebar need not be disengaged to switch modes. 
     Certain embodiments of the present invention may comprise commercially available ratchet mechanisms and tool heads constructed to be compatible with commercially available ratchet mechanisms. Other embodiments may comprise ratchet mechanisms specifically designed for Hickey bar application and for the high loads necessary to bend rebar. 
     An example of a commercially available female ratchet drive is Proto® Industrial Tools item number J5649FW ¾″ Ratchet Female Drive with 20″ handle, and an example of a commercially available male ratchet drive is Snap-On® item L873 1″ Square Drive Sealed Ratchet Head. There are many others. 
     With reference to  FIG. 2 e   , the drive portion of a typical commercially available ratchet mechanism is shown, having a square drive peg  25 . Drive peg  25  has lateral sides  29 , beveled top edges and corners forming round top surface  28 , a round shoulder  27  at the base of the peg, and a releasable lock pin  26  or equivalent lock ball for engaging a corresponding hole or indentation in the tool head. The peg&#39;s longitudinal axis corresponds with its axis of rotation when it rotates relative to the Hickey bar handle. The “drive axis” or “axis of rotation” may refer to the axis of rotation of a male drive ratchet or female drive ratchet relative to the handle. The tool head of the present invention may be configured to be releasably attachable to the drive in like manner as sockets are in commercially available ratcheting socket wrench sets, and may comprise a hole or indentation in the tool head for receiving releasable lock pin  26  or equivalent lock ball. 
     In another embodiment of the present invention, the tool head is securely fastened to the drive peg using any suitable manner for secure attachment, such as a pinned joint. With reference to  FIGS. 2 a  and 3 a   , tool head  30  may be provided with a pin hole  36 . The drive peg may be provided with a corresponding pin hole (not shown) aligned with pin hole  36 . A pin (not shown) may be installed in the pin holes, said pin having an interference fit with the holes, to form a secure joint. This embodiment may comprise a drive without a releasable lock means such as a releasable pin  26  or equivalent releasable ball. Such a non-releasable joint may be preferred to ensure robust connection and prevent inadvertent release of the tool head from the ratchet mechanism under the rigorous loading conditions often encountered in service. 
     In other embodiments, the present invention may comprise fixed drives with no ratchet mechanism. In yet other embodiments, the tool head may be integral to the drive and may be integral to the handle. 
     With reference to  FIGS. 3 a -3 c   , a preferred embodiment of the tool head may comprise a base  31  having upward facing surface  32  and a plurality of upwardly extending members  34  having lateral sides  35 . The spaces between sides  35  of members  34  form transverse channels  41 ,  42  and  43 , each channel extending across the tool head. Each member  34  may have different dimensions than other members  34  as necessary to form channels of desired width. In  FIG. 3 c   , channel  41  is wider than channel  42 , and channel  42  is wider than channel  43 . Member  34  between channels  41  and  42  has a smaller cross section than the member between channels  42  and  43 . 
     The tool head may comprise a spacer  33  extending below base  31 , said spacer for contacting the ratchet drive and maintaining clearance between the base and ratchet mechanism. 
     The tool head of the present invention may be manufactured from a block by machining away the material necessary to form channels of desired dimension. Thus, members  34  are formed from remaining material of the block between the channels, as shown in  FIG. 3 a   . Thus the present invention provides for improved manufacturing methods. Most efficient use of materials is achieved, which allows for smaller tool heads and provides stronger upward extending members  34 . Side surfaces  35  of members  34  contact the rebar during bending operations and transmit the bending torque to the rebar. Members  34  and surfaces  35  have material properties sufficient to withstand these forces without undue deformation. 
     In some embodiments, the channels may comprise a round hole bored transversely through the tool head. The hole may be manufactured in any desirable cross sectional shape. In those embodiments, the channels are not open to the top of the tool head. 
     The tool head of the present invention may comprise a single piece of material, thus providing a more robust tool head and eliminating assembly steps such as assembling pins to the tool head as may be necessary for the Hickey bar of  FIG. 5   a.    
     The tool head may comprise metal or any other suitable material. The tool head may comprise steel and may comprise tool steel. 
     In the embodiment shown in  FIGS. 3 a -3 c   , the channel sides are opened to the top of the tool head so that the tool head may receive sideways insertion of rebar through the top of the tool head. The tool head may be positioned adjacent to a length of rebar at mid span, with the top of the head facing the side of the rebar and with a channel aligned with the rebar. The rebar and/or Hickey may then be moved sideways with respect to the rebar to insert the rebar into the channel, thus engaging the head and rebar for subsequent bending operations.  FIGS. 4 a  and 4 b    show a Hickey bar of the present invention engaged with a rebar, shown after the bending operation has taken place. 
     The “sideways” directional reference for describing relative movement or special relationship of the tool and rebar indicates sideways with respect to the rebar. 
     In an alternate embodiment, the top side of the channel may be closed or have an undersized opening. In that case, the rebar may be received endwise through the side of the tool head into an open end of a channel. In this alternate embodiment, the bar is securely captured from unintended disengagement out from the top of the tool head during bending operations. 
     The tool head may comprise a plurality of channels. A channel may intersect one or more other channels. The embodiment of  FIG. 3 c    comprises three channels, each having a different width than the other two, and all intersecting in the middle of the tool head. Channel widths may be sized to fit standard size rebar. For example, channels  41 ,  42  and  43  may be sized to fit three different standard sizes, such as standard bar sizes #5, #4, and #3, respectively. Channel widths may be sized to provide a clearance fit with the intended bar size diameter. 
     With further reference to  FIGS. 1-3   b , the tool head is provided with a square opening  44  for receiving square drive peg  25 . Pin hole  36  is provided for alignment with a corresponding pin hole (not shown) in the drive peg and receiving a pin to securely affix the tool head to the drive peg. In a preferred embodiment, opening  44  is sized for compatibility with a one inch (1″) square drive. Opening  44  may be sized for compatibility with other drive sizes. For example, it may be sized for compatibility with other standard drive sizes. 
     In other embodiments, opening  44  may be of any shape to correspond with the shape of the desired drive, such as any polygonal shape or splined shape. 
     In another embodiment, the tool head may be configured to be compatible with a female drive, such as a ratchet wrench with a female drive. In this embodiment, the base of the tool head may comprise a downward extension of polygonal cross section corresponding to the shape of the opening of the female drive. Said downward extension may be square, hexagonal, or any other shape to correspond with the shape of the desired drive, such as any standard size drive. The cross section may be of a splined shape. 
     The term “coupling” herein may refer to a male or female feature of the tool head for connecting with a corresponding female or male drive, respectively. 
     With reference to  FIGS. 3 a -3 c   , the external sides of base portion  31  may be engaged directly by a driving device. The hexagonal shape of the tool head of  FIGS. 3 a -3 c    is particularly suitable for such engagement. For example, an open ended wrench of appropriate size could engage the hexagonal shape. 
     In other embodiments, the bottom portion of the base may be provided in any shape to facilitate engagement with a driving device of desired shape. 
     A driving device may be any device suitable for attaching to and applying torque to the tool head. 
     In the embodiment of  FIGS. 1-3   c , channels  41 ,  42  and  43  intersect the drive axis of rotation. Thus, when the Hickey bar is in operational engagement with a length of rebar, the axis of rotation of the drive intersects the rebar. The drive axis of rotation is perpendicular to the longitudinal axis of rebar. This tool head configuration and geometric relationship between the Hickey bar and rebar provides efficiencies and advantages, such as mechanical advantages, operational advantages, tool design efficiencies, manufacturing efficiencies, space utilization advantages, and other advantages. 
     Two Hickey bars of the present invention may be used together to bend rebar by engaging the rebar at two locations and applying torque to each tool head in opposite directions. 
     A hickey bar of the present invention may comprise a handle attached to a ratchet attached to a tool head type shown in  FIGS. 5 a -6 b   , or any other tool head design adapted for engagement with and bending of rebar. 
     A kit of the present invention may comprise one or more a separate handles, ratchet mechanisms, tool heads and drive size adapters. Another kit may comprise one or more preassembled handle and tool head assemblies. 
     The device of the present invention may be used to engage and bend any long, slender, bendable object, such as threaded rods, grounding rods, and pipe. 
     While the invention has been particularly shown and described with reference to certain embodiments, it will be understood by those skilled in the art that various changes in form and details may be made to the invention without departing from the spirit and scope of the invention as described in the following claims.