Abstract:
An unloading apparatus for unloading a roll of material such as carpet from a transport vehicle comprising a support frame having a rail running lengthwise above a roll of material within the cargo bay. A trolley system is movably attached to one end of the rail for traversing along the rail toward the rear of the vehicle. A lifting device, such as a hoist cable, attaches the trolley system to a first end a mandrel tube that passes through the roll material being supported. The tube may be adjustable in length and includes a telescoping member, which is at the end attached to the lifting device. A mobile support jack is situated outside of the cargo bay for lifting and supporting the second end of the tube when removing the roll material from the vehicle. The support jack may be moved away from the vehicle while supporting the roll of material at its second end. Additionally, a mobile support pedestal or additional jack member may be provided to support the first end of the tube when detached from the trolley system. Both the support jack and support pedestal may be provided bearing members to permit the rolled material to rotate for unrolling.

Description:
PRIORITY CLAIM  
       [0001]    The present application claims benefit of the filing date of the U.S. provisional patent application Ser. No. 60/461,102 filed Apr. 8, 2003. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of the Invention  
           [0003]    The present invention relates to an apparatus for handling carpet. More specifically, this invention relates to an apparatus for unloading a carpet roll or rolled other materials from a transport vehicle at a job site where heavy unloading equipment and lifts are generally unavailable. The carpet unloading apparatus enables one or more individuals to handle rolls of carpet without the excessive lifting and straining generally associated with such work.  
           [0004]    2. Description of the Prior Art  
           [0005]    Rolls of carpeting are commonly very large, bulky and heavy. Therefore, to manually handle these rolls is very strenuous, tiring and undesirable, as well as a potential cause of back injuries or muscle strain. Unfortunately, the type of heavy equipment usually associated with handling carpet rolls is generally unavailable at a job site where carpet in being installed. Thus, leaving a burdensome task to the individuals involved that has not been overcome by the numerous methodologies implemented to address carpet roll handling. In particular, none of the prior attempts satisfactorily provide for carpet roll handling at remote work sites.  
           [0006]    U.S. Pat. No. 3,750,811 issued to Anderson discloses a carpet unloading and transporting assembly that comprises an elongate rectangular frame equipped with electric winches and cables. A support leg extending downward at each of the four corners supports this large frame. Each of these legs has a caster attached for mobility. The Anderson apparatus is placed at the rear of a transport vehicle where a cable is placed around a roll of carpet from outside the vehicle. Then, with another set of cables and a winch, the roll is lifted off the floor. The apparatus can then be rolled to another location in a warehouse carrying the carpet with it. While beneficial for its intended use, this equipment is specifically designed for a store or warehouse setting and is not suitable for relocation and use at a jobsite.  
           [0007]    In another example, U.S. Pat. No. 2,702,139 issued to Faustine illustrates a similar apparatus to Anderson above that too is unsuitable for relocation. In yet another example, U.S. Pat. No. 4,396,166 issued to Kollman, provides an apparatus inside a closed-in cargo type trailer. This device consists of a closed-in trailer large enough to carry several rolls of carpet with a rear door through which the rolls can be pulled via an electric power winch mounted inside the trailer. Once the carpet is inside the trailer it can be suspended off the floor by a lifting mechanism mounted inside the trailer, then the end of the roll can be fed as it is unrolled through an opening in the side of the trailer long enough to allow the width of the carpet to pass through. This design allow for the carpet to be cut in lengths as needed while the remainder of the roll is suspended inside the vehicle. While this is a very impressive design, the cost factor would be so great as to render it unaffordable or impractical for many would be users.  
           [0008]    Accordingly, a need exists for a carpet-unloading apparatus that remains with a transport vehicle so that it will be available when needed to unload a carpet roll or the like at a work site. It is also necessary that it be user-friendly, quick and easy to operate. It should also be relatively inexpensive and affordable enough for those who need it. This present invention will meet all these necessities.  
         BRIEF SUMMARY OF THE INVENTION  
         [0009]    The present invention provides for a novel and unique user-friendly carpet unloading device, part of which will be removably attached and remain inside the vehicle to which it is assigned. The other parts are set up on the outside of the vehicle for use, after which they are folded together and stored in some small area until further needed.  
           [0010]    The apparatus of the invention is small, lightweight and can be assembled into a folding arrangement or stored in very little space in the vehicle while being transported. It is light enough to enable one person to operate. It is relatively inexpensive to manufacture which makes it very affordable. It is very safe and requires very little physical strength to unload a roll of carpet.  
           [0011]    With the use of this present invention, an operator is able to mechanically lift a roll of carpet, remove it from the vehicle and have it resting on an elongated tube, which extends lengthwise through the center of the roll. This tube is then supported on each end by a ridged pedestal or jack stand or combination thereof. This stand will hold the roll of carpet off the floor where it can be unrolled and cut into the desired lengths.  
           [0012]    The present invention is comprised of a framework to be securely attached to the inside of the vehicle. This framework consists of, among other things, a series of columns, or posts that extend upward from the floor to near the top of the vehicle. These columns, or posts are designed to be adjustable in length and can be adjusted to the height of the vehicle in which they are installed. The size and number of these columns are determined by the length of the overhead rail and the weight they are to support. These columns are spaced apart one from another along the side and relative to the wall of the transport vehicle. Each column has a corresponding column of like configuration directly across the vehicle and relative to the opposite wall. Each of these columns has a corresponding cross-member that attaches at the top of teach column and extends in a cross direction toward the center of the vehicle. The cross-members are also adjustable in length and may be adjusted to the width of the vehicle in which it is installed. Each of these corresponding cross-members is then attached to an upper mounting bracket at the top center of the vehicle. Thus, when all these components are connected they make up a set of supports and form a structural arch across the vehicle. This is repeated as often as necessary to support the weight that is to be moved along the top rail.  
           [0013]    The top rail is a long rail or track suspended from the bottom center of each upper mounting bracket via a tie rod or hanger. These tie rods or hangers should be constructed in a manner that will provide for the top rail to be made ridged to the supporting framework.  
           [0014]    A trolley is placed on the rail. This trolley should be suitable for use on this rail and sufficient to move the load suspended beneath it with a relatively minimal amount of force. A hoist sufficient to lift, hold and lower the expected load is attached to the trolley and an attaching devise is lowered down to the load.  
           [0015]    The device of the present invention provides for an adjustable length tube with a telescoping mechanism at one end and a shaft or portion of the tube extending outward from the other while holding a roll of carpet. This tube can be coupled together or separated at approximately center ways. In the outermost section of this tube is stored a slightly smaller and shorter length of similar tube. This inside tube can be extended out in various lengths and locked in place then inserted into the other section of the outer tube and locked in place on that end. This feature allows for the tube to be adjusted to proper length corresponding to the carpet being moved. This tube, when adjusted to the proper length and locked in place can be passed lengthwise through a roll of carpet. The telescoping mechanism of the tube can then be attached to the lower end of the hoist that is attached at the top to the trolley. In one embodiment, a shaft at the outermost end of this tube may be designed to pass through a collar mounted pilot bearing located near the top of a jack. This jack is easily affixed on a stand that is also equipped with large swivel casters that provides for the stand to be easily rolled in any direction while bearing the load of a roll of carpet. These casters are also provided with a locking brake that may be applied when movement is unsuitable. A second stand is also provided that is very similar to the first. The second stand may be provided with a removable jack and include large swivel casters like the first stand. In an alternative embodiment, the second stand may have a ridged pedestal that can be raised or lowered as desired, in lieu of a jack. The carpet roll will generally roll freely about the tube. As an enhancement, the pedestal may include rollers at the top for the tube to rest on once it has been removed from the vehicle. Thus, the tube is passed length ways through a roll of carpet then attached at the innermost end to the hoist and at the outer end to the jack that is affixed to a stand equipped with casters.  
           [0016]    Now when the hoist is raised at one end, the jack at the other end of the roll will be lifted from the surface where it lay. After the roll has been lifted it can be easily pulled in an outwardly direction. At this time the jack stand that is on casters and the overhead trolley will begin to roll, thus removing the carpet from the vehicle. When the trolley reaches the outer limit of the rail, the trolley will stop. At this time the telescoping mechanism can be released. This will allow the roll to be pulled further out until the carpet is clear of the vehicle, then by lowering the hoist the tube can be lowered onto the second stand or jack. After carpet is lowered onto the second jack, the hoist can be disconnected from the telescoping mechanism. The telescoping mechanism can now be pushed back into the tube and the vehicle removed, or, because of the casters at each end of the carpet roll, the carpet roll may be removed to a more suitable location. Because this tube is resting on rollers at one end and a bearing at the other, or alternatively, lateral supports extending from the jack stands, carpet roll or tube may be easily rotated as the carpet is pulled off the roll. The casters can also be locked in position in order to hold the stands while the carpet is unrolled.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    [0017]FIG. 1 is a perspective view illustrating the present carpet unloading apparatus.  
         [0018]    [0018]FIGS. 2 a ,  2   b  and  2   c  are side plan views illustrating the operation of the present carpet unloading apparatus.  
         [0019]    [0019]FIGS. 3 a ,  3   b  and  3   c  are front plan assembly views illustrating the assembly of the support frame of the present invention.  
         [0020]    [0020]FIG. 4 a  is a perspective view illustrating the assembly of the overhead support rail of the invention and trolley system.  
         [0021]    [0021]FIG. 4 b  is a front side sectional view illustrating the assembly of trolley system of the present invention.  
         [0022]    [0022]FIG. 5 is a side plan view illustrating the assembly of the carpet roll supporting tube, overhead rail, and hoist of the present invention.  
         [0023]    [0023]FIGS. 6 a ,  6   b  and  6   c  are side plan assembly views illustrating the assembly of the supporting tube of the invention, including telescoping members.  
         [0024]    [0024]FIG. 7 is a side plan view illustrating an alternative embodiment of the present carpet unloading apparatus in an operative condition in which a carpet roll has been unloaded onto a pair of jack stands.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0025]    Referring now to the drawings, FIG. 1 illustrates a preferred embodiment of the present invention. A carpet unloading apparatus for unloading a roll of material such as a carpet roll  10  from a transport vehicle  12  is provided comprising a support frame structure  14 , a carpet roll support tube structure  42 , and external means  50  and  58  for supporting a carpet roll via the carpet roll support tube structure once the carpet roll is removed from a vehicle. The support frame structure stands within a rear cargo bay  13  of the transport vehicle  12  and supports a trolley system  34  and hoist systems  36  that traverses along an overhead rail  26  to remove a carpet roll from the transport vehicle and place the carpet roll securely on the external support means.  
         [0026]    More particularly, a removable and independent support frame structure  14  is provided having vertically oriented columns  16  for supporting the trolley system  34  and hoist systems  36  above a carpet roll  10  situated within the rear cargo bay  13  of the transport vehicle  12 . Several columns  16 L are located along the left sidewall of the vehicle, and several columns  16 R are located opposite left side columns along the right side wall of the vehicle. The columns  16  rest on the floor  18  of the vehicle  12  and are supported thereby, but not necessarily affixed to the vehicle. Ties or braces  17  attached from the floor, ceiling or sidewalls of the vehicle cargo bay  13  may further support the columns  16 . Sufficient columns  16  are provided to ensure adequate support of the very heavy carpet rolls  10  or the like to be handled by the apparatus. The columns  16  are placed very near to the sidewalls  22 ,  24  of the vehicle in order to maximize the workspace provided about the carpet roll  10  stored within the rear cargo bay  13 .  
         [0027]    The column members  16  as shown in FIGS. 1, 3 a  and  3   c , are adjustable for height to fit into vehicle cargo bays  13  of varying heights. In particular, the columns  16  may comprise first column members  16   a R and  16   a L and second column members  16   b R and  16   b L. First column members  16   a R,  16   a L may have a smaller circumference that the second column members  16   b R,  16   b L for insertion of first column members into the second column members. Alternatively, a lower portion of the first column members  16   a R,  16   a L may be swedged or have reduced diameter for insertion into second column members  16   b R,  16   b L. Means for fixing the position of the first column members within the second column members is provided to fix the height of the column members  16 . As shown in FIG. 3 c , a bolt  19  may be inserted into an aperture in each second column member  16   b R,  16   b L and tightened to bear against the respective first column member  16   a R,  16   a L contained within the second column member such that the first column member will not slide and will remain in a fixed position.  
         [0028]    The support frame structure  14  includes cross-members  28  that span from the left column members  16 L to the right column members  16 R to provide support above the carpet roll  10 . The columns  16  may have angled upper portions  21  to intersect and connect to the cross-members  28 . In one embodiment as illustrated in FIGS. 3 a  and  3   b , the cross-members  28  comprise the angled portion  21  of the columns  16 , a pair of intermediate adjusting members  28   a ,  28   b  and a center connecting member  28   c , which may be slightly arched to fit the contour of a vehicle cargo bay  13 , increase vertical space available, and align each intermediate member  28   a ,  28   b  with the center connecting member  28   c  and angled portions  21  of the columns  16 . Each intermediate adjusting member  28   a ,  28   b  connects the angled portion  21  of each respective column  16  to the center connecting member  28   c  such that a single horizontal span across the cargo bay  13  of the vehicle  12  is created. The connection of the intermediate members  28   a ,  28   b  may be accomplished by providing a tubular receptacle on each end of the intermediate members that receives the respective ends of the columns  16  or center connecting member  28   c.  Changing the amount of the column  16  or center connecting member  28   c  that is inserted into the intermediate member receptacle may adjust the length of the span. Bolts  29  or affixing devices are provided for securing the intermediate members, and, thereby, defining the length of the cross-members  28 .  
         [0029]    The cross-members  28  support a rail  26 , which runs lengthwise along the ceiling of the rear cargo bay  13  of the transport vehicle  12 . The depicted rail  26  comprises a long narrow angle iron situated with the ends  27  of the angle iron pointing downwards. The rail  26  is attached to the cross-members  28  by a tie rod  32  that hangs from the center of the cross-members, and a nut or other method is used to attach the rail to tie rod. The tie rod  32  provides for adequate spacing between the cross-members  28  and rail  26  for the provision of a trolley system  34 .  
         [0030]    As shown in FIG. 5, the trolley system  34  may run along the lengthwise rail  26  via bearing wheels  34   a.  An attaching device  34   b  such as a bolt and nut combination attaches each bearing wheel  34   a  above the ends  27  of the angle iron of the rail  26  and the bolt may provide a shaft for the bearing wheels to rotate about. The trolley system  34  further includes a short angle iron member  34   d  with the ends pointing upwards for attachment of the bearing wheels  34   a  above the rail  26 . The short angle iron member  34   d  is suspended below the rail  26  by the bearing wheels  34   a  and provides a support for a hoist and pulley system  36   a  that may be attached to the short angle iron by an eye bolt  34   c  attached thereto. The bearing wheels  34   a  roll along the upper edge of the rail  26  and traverse the rail for movement of a supported carpet roll  10  or the like. Thus, the trolley system  34  may be attached to the end of the carpet roll  10  via a suitable device such as a cable  38  with hoist and pulley  36   a.  The trolley  34  would support the carpet roll  10  at the end closest to the inward portion of the vehicle&#39;s rear cargo bay  13 . When the carpet roll  10  is removed from the vehicle&#39;s rear cargo bay  13 , the trolley system  34  allows the carpet roll to exit the rear of the vehicle  12  while the trolley moves toward the rear of the vehicle along the rail  26 . A hook or attaching device  40  connects the cable  38  to the end of tube that supports the carpet roll.  
         [0031]    The elongate tube  42  shown in FIGS. 5 and 6 a ,  6   b  and  6   c  may comprise a first square tube member  42   a  and second square tube member  42   b  having a connecting tube member  48  between them, a telescoping tube member  44 , and a shaft  46 . The connecting member  48  may be received by the respective open ends of the first and second square tube members  42   a ,  42   b  and secured between the tube members by set screws  45  or other securing mechanism such as spring loaded lock buttons. By loosening the setscrews  45 , the length of the elongate tube  42  may be varied according to the length of carpet roll  10  being transported and handled, such as 12 ft or 15 ft.  
         [0032]    At the end of the elongate tube  42  that is positioned toward the inward portion of the vehicle&#39;s rear cargo bay  13 , the elongate tube is provided a telescoping tube member  44 . The telescoping tube member  44  may be housed partially within the walls of the second square tube member  42   b  and extend from the end of the second square tube member to increase the overall length of the tube  42 . A first bearing member  47  at the inward end of the telescoping tube member  44  promotes the efficient telescoping of the telescoping tube member. The first bearing member  47  as shown includes a bearing wheel  49  rotationally attached to the inward end of the telescoping tube member  44  and contained within the square tube member  42   b.  The bearing wheel  49  is situated between the inside corners of the square tube member  42   b , which creates a track for longitudinal movement of the wheel during the telescoping function of the telescoping tube member  44 , while limiting the latitudinal movement of the wheel. A second bearing member  51  at the end of the tube  42  and situated about the telescoping tube member  44  further supports and promotes efficient telescoping of the telescoping tube member. The second bearing member  51  is shown at the end of the tube  42  and is attached thereto. The telescoping tube member  44  rolls along the second bearing member when extended to telescope from the end of the tube.  
         [0033]    The carpet roll  10  is removed from the vehicle&#39;s rear cargo bay  13  using the trolley system  34 . Before removal of the carpet roll  10 , a jack  50  supports the outward end of the tube  42 . One preferred jack  50  as shown in FIG. 2 includes a collar with pilot bearing  52 . The shaft  46  extending from the outward end of the tube  42  is inserted into the collar  52 . The shaft  46  may rotate as a result of the supporting pilot bearing  52 .  
         [0034]    [0034]FIG. 7 shows an alternative arrangement of a first jack  68  and second jack  70  in which the jacks include supports  76 A and  76 B extending laterally to a side of the jacks for supporting the tube  42  that the carpet roll is on. In this arrangement, the jacks  68  and  70  support the tube to the side and offset from the center of the jacks.  
         [0035]    Once the jack  50  or  68  supports the outward end of the tube  42 , the jack  50  is moved away from the rear of the vehicle  12 , thus moving the carpet roll  10  out of the vehicle. The carpet roll  10 , which is supported at the inward end of the tube  42  by the moving trolley system  34 , does not completely exit the vehicle  12  because the trolley may only traverse to the end of the rail  26 . Once at the end of the rail  26 , a provided release mechanism, such as a latch pin, is released to permit telescoping of the telescoping tube member  44  to extend the tube and further remove the carpet roll  10  from the rear of the vehicle  12 . The hook or attaching device  40 , which connects the cable to the end of tube  42  to support the carpet roll  10 , attaches to the telescoping tube member  44 . Thus, the carpet roll  10  may be separated from the vehicle  12  via the telescoping tube member  44 , and, the tube  42  then disconnected from hoist cable  38 .  
         [0036]    After disconnecting the tube  42  from the hoist cable  38 , the user may rest the end of the carpet roll  10  opposite the end supported by the jack  50  on an external pedestal  58 . The carpet roll  10  supported by the jack  50  and pedestal  58  may be positioned for using the roll of carpet. Rolling stands  54 A and  54 B (or  72 A and  72 B) along with several casters  56   a  and  56   b  that are situated beneath the jack and pedestal (or combination of jacks as in FIG. 7) permit movement of the supported carpet roll to a suitable work location. Once situated, stabilizers  74 A and  74 B may be provided to extend from each side of the stands  72 A and  72 B. These stabilizers may be arranged to telescope from the center beam of the stands and turned up to retract into the center beam when not in use. A locking mechanism may be arranged between the stabilizers and stand to affix the stabilizers into the telescoped or retracted positions. The pedestal  58  may have rollers  60  that support the end of the tube  42 . The combination of the pilot bearing  52  supporting the shaft  46  at one end of the tube  42  and the rollers  60  supporting the telescoping tube member  44  at the other end of the tube permit the unrolling of the carpet roll  10  after it has been removed completely from the vehicle  12 . Alternatively, the inward end of the tube  42  could remain attached to the vehicle  12 . A bearing member may be provided on the telescoping tube member  44  to permit the tube  42  to rotate while attached to the vehicle  12  via cable  38  or other means, thus permitting unrolling of the carpet. In another embodiment shown in FIG. 7, each end of the tube  42  may be supported by the brackets  76 A and  76 B. Thereby, the roll of carpet may roll freely about the tube  42 .  
         [0037]    It should be apparent to those skilled in the art that modifications and variations can be made to the embodiments of the invention described herein without departing from the scope and spirit of the invention as set forth in the claims and their equivalents.