Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not Applicable. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable. 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH OR DEVELOPMENT Not Applicable. 
     BACKGROUND OF THE INVENTION 
       [0003]    1. Field of the Invention 
         [0004]    The present invention relates to deck construction and particularly to a deck board remover and installation alignment tool which is actuated by a portable drill motor; the device comprises a drill motor attachment having a drill-actuated old board lifter, nail puller and new board straightening aligning, and holding clamp. 
         [0005]    2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98 
         [0006]    Deck floors generally comprise of a series of boards laid side-by-side on top of and perpendicular to the support joists of the deck. The deck boards usually nailed to the joists. For safety and aesthetic purposes, deck boards need to be replaced when they deteriorate. The boards are usually removed with a pry bar. None of the prior art devices provide an electric drill powered device combining tools for removing old deck boards and nails and for aligning and holding a new deck board for installation. 
         [0007]    U.S. Pat. No. 2,796,232, issued Jun. 18, 1957 to Steffanus, indicates a nail puller which is used with a hand drill. The nail puller comprises a two-part rotational body having an external anchor means, an internal nail-removing helix channel, a chuck-engaging shank, and a nail ejecting passage. The rotational force of the hand drill causes the nail to rise up through the helix channel and out through the ejection passageway. 
         [0008]    U.S. Patent Application No. 20070175176, published Aug. 2, 2007 by Lane, describes a deck jig which comprises a decking board installation tool which keeps the space between the edges of the decking boards the same throughout the decking board installation. 
         [0009]    U.S. Pat. No. 6,971,635, issued Dec. 6, 2005 to Foster, is for a deck board setting assembly which includes a bracket assembly having a channel therein for removably receiving an upper edge of a deck stud. The bracket assembly has a forward side and a rearward side. A pivot rod is rotatably coupled to and extends away from the bracket assembly. The pivot rod is orientated perpendicular to the channel. A lever assembly is pivotally attached to the pivot rod. The lever assembly is selectively rotated in a first direction forward of the bracket assembly or in a second direction rearward of the bracket assembly. A locking assembly is attached to the lever assembly and the bracket assembly for selectively preventing rotation of the lever assembly in the second direction. The lever assembly may be rotated in the first direction such that the lever assembly abuts a loose horizontal board and urges the loose horizontal board away from the bracket assembly. 
         [0010]    U.S. Pat. No. 4,736,927, issued Apr. 12, 1988 to Clancy, provides a mechanical linear force actuator which is light weight and manipulatable and utilizes linear motion for push or pull forces while maintaining a constant overall length. The mechanical force producing mechanism comprises a linear actuator mechanism and a linear motion shaft mounted parallel to one another. The linear motion shaft is connected to a stationary or fixed housing and to a movable housing where the movable housing is mechanically actuated through actuator mechanism by either manual means or motor means. The housings are adapted to releasably receive a variety of jaw or pulling elements adapted for clamping or prying action. The stationary housing is adapted to be pivotally mounted to permit an angular position of the housing to allow the tool to adapt to skewed interfaces. The actuator mechanism is operated through a gear train to obtain linear motion of the actuator mechanism. 
         [0011]    U.S. Pat. No. 6,015,136, issued Jan. 18, 2000 to Benudiz, shows a portable fastener removal apparatus for removing an elongate fastener having an axis of radial symmetry from a structure in which the fastener is embedded. The fastener removal apparatus is provided with a housing having an elongate channel which defines a housing axis. The housing is sized and configured to be positionable upon the structure such that the housing axis is coaxially aligned with the axis of radial symmetry. The fastener removal apparatus is further provided with a force transfer member which is movably attached to the housing and has an engagement portion which is concentrically positioned within the channel and formed to releasably engage the fastener. The fastener removal apparatus is further provided with a jack which is attached to the housing and has a force transmission member which is cooperatively engaged to the force transfer member and reciprocally movable along a lifting axis which extends in generally parallel relation to the housing axis. The actuation of the jack, subsequent to the engagement of the engagement portion to the fastener and positioning of the housing upon the structure, results in the movement of the force transmission member along the lifting axis in a direction away from the structure, thereby imparting a lifting force to the force transfer member which moves the engagement portion along the housing axis in a direction away from the structure, thus removing the fastener from therewithin. 
         [0012]    U.S. Pat. No. 2,900,169, issued Aug. 18, 1959 to White, claims a power driven automatic bolt puller which includes a threaded shaft having attached thereto a collet for engaging a bolt head and a nut threadingly engaged on the shaft for urging the shaft through a barrel in the bolt puller, the nut being in the form of an elongated sleeve intended to receive the threaded portion of the bolt. 
         [0013]    U.S. Pat. No. 1,094,449, issued Apr. 28, 1914 to Lauri, describes a floor clamping device that consists in a hand screw-secured, fined anchor which is joined by a threaded bolt to a turnbuckle coupler, which is in turn joined to a threaded bolt and then to a swivel mounted, plain rectangular head. The turnbuckle coupler is rotated by manipulation of a perpendicularly projecting handle that is placed in one of several holes girdling the turnbuckle coupler. U.S. Pat. No. 3,152,787, issued Oct. 13, 1964 to Timmons, discloses a motorized floor jack which pulls floor boards into position and holds them until they are nailed. The device comprises a wheeled frame, a control box, a reversible electric motor, a threaded pulling shaft moved by the motor and a board pulling member attached to the distal shaft end by a chain. 
         [0014]    U.S. Pat. No. 131,050, issued Sep. 3, 1872 to Butler, puts forth a spike extractor comprising a standing frame provided with a vertically oriented jack-screw which operates an upright claw-bar provided with a clutch of requisite form and dimension to grasp the head of a railroad spike. 
         [0015]    What is needed is an electric drill powered device combining tools for removing old deck boards and nails and for straightening, aligning and holding a new deck board for installation. 
       BRIEF SUMMARY OF THE INVENTION 
       [0016]    An object of the present invention is to provide a multiple arm tool powered by an electric drill combining tools for removing old deck boards and nails and for straightening, aligning and holding a new deck board for installation. 
         [0017]    In brief, the invention is a mechanical apparatus with the main functions of removing decking planks from framing members, pulling out the nails left behind after removing the planks, and aiding in the installation of new decking planks by providing a means to force bent planks into position, straighten them, and hold them in place for fastening. 
         [0018]    The tool is designed to incorporate all of these functions into one apparatus and is actuated by an ordinary power drill attached to the end of the shaft at the top of the tool. Much of the manual labor of removing old decking is eliminated, while speeding up the process and can easily be done from a standing position. 
         [0019]    In the board-straightening mode, far more force can be applied and with much less effort than with any manually operated bending device, and provides a further advantage of holding the bent board in the desired position until released, leaving both hands free to fasten the board in place. 
         [0020]    Replaceable lifting arms enables different arm sizes and different spacing between the two lifting arms to be used for different jobs. 
         [0021]    A pair of pivotable lifting arms with individually pivotable arms enables the use of one or both lifting arms and enables the lifting arms to be pivoted up for storage. 
         [0022]    The purpose of the device is to provide a multiple arm tool powered by an electric drill combining tools for removing old deck boards and nails and for aligning, straightening, and holding a new deck board for installation. 
         [0023]    An advantage of the present invention is it provides an easy, mechanical means to remove old deck boards. 
         [0024]    Another advantage of the present invention is it provides an easy, mechanical means to remove nails that remain after old deck boards are removed. 
         [0025]    One more advantage of the present invention is it provides an easy, mechanical means to align, straighten, and hold new deck boards for installation. 
         [0026]    An additional advantage of the present invention is it allows an installer to have both hands free to nail in a new deck board, as the device holds the board in place for the installer. 
         [0027]    A further advantage of the present invention is that removed nails come out of the deck beams straight and ready to re-use. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0028]    These and other details of my invention will be described in connection with the accompanying drawings, which are furnished only by way of illustration and not in limitation of the invention, and in which drawings: 
           [0029]      FIG. 1  is an exploded elevational view of the components of the multi-function deck tool of the present invention with the components separated; 
           [0030]      FIG. 2  is a side elevational view of the assembled multi-function deck tool of the present invention positioned with the lifting arms straddling a deck board support beam and positioned under the deck board for lifting the deck board showing a side view of the lifting arms; 
           [0031]      FIG. 3  is a rear elevational view of the assembled multi-function deck tool of  FIG. 2  positioned with the lifting arms straddling a deck board support beam and positioned under the deck board for lifting the deck board showing an end view of the lifting arms; 
           [0032]      FIG. 4  is a rear elevational view of the assembled multi-function deck tool of  FIG. 2  positioned with the lifting arms straddling a deck board support beam and shown lifting the deck board showing an end view of the lifting arms; 
           [0033]      FIG. 5  is a side elevational view of the assembled multi-function deck tool of  FIG. 2  positioned with the bottom flat head of the inner structural tube resting transversely on a deck board support beam showing the nail lifting flat head of the inner structural tube sliding toward a nail protruding from the deck board support beam to engage the nail in the nail slot; 
           [0034]      FIG. 6  is a front elevational view of the assembled multi-function deck tool of  FIG. 2  positioned with the bottom flat head of the inner structural tube resting on a deck board support beam showing a front view of the nail lifting flat head of the inner structural tube with a nail in the nail slot; 
           [0035]      FIG. 7  is a front elevational view of the assembled multi-function deck tool of  FIG. 2  positioned with the lifting arms straddling a deck board support beam and the bottom of the outer structural tube resting on a deck board support beam showing a front view of the nail lifting flat bottom of the inner structural tube lifting a nail in the nail slot to pull the nail from the beam; 
           [0036]      FIG. 8  is a side elevational view of the assembled multi-function deck tool of the present invention including the aligning arm attached to the flat end of the inner structural tube, with the multi-function deck tool positioned with the outer structural tube and drill oriented horizontally resting on the nailed deck boards, the lifting arms straddling a deck board support beam and hooked over an unattached deck board with an aligning plate of the aligning arm braced against a nailed deck board; 
           [0037]      FIG. 9  is a side elevational view of the assembled multi-function deck tool of the present invention including the aligning arm attached to the flat end of the inner structural tube, with the multi-function deck tool positioned with the outer structural tube and drill oriented horizontally resting on the nailed deck boards, the lifting arms straddling a deck board support beam and hooked over an unattached deck board with an aligning plate of the aligning arm braced against a nailed deck board, showing the lifting arms straightening the unattached deck board and pulling it into alignment with the attached nailed deck board for attaching the unattached deck board to the beams; 
           [0038]      FIG. 10  is a side elevational view of the assembled multi-function deck tool of the present invention with the aligning arm reversed so that the aligning plate facing up is hooked between the lifting arms and the attaching plate facing down is hooked behind an attached deck nailed board adjacent to a building wall with the multi-function deck tool positioned with the outer structural tube and drill oriented horizontally on a deck board support beam and with the flat end of the inner structural tube pressing against an unattached deck board straightening the unattached deck board and pushing it into alignment with the attached nailed deck board for attaching the unattached deck board to the beams; 
           [0039]      FIG. 11  is a side elevational view of the outer structural tube of the multi-function deck tool of the present invention held vertically and a replaceable lifting fork component with the lifting fork sleeve aligned for sliding down over the outer structural tube for assembly to enable different lifting arm sizes and different spacing between the two lifting arms to be used for different jobs; 
           [0040]      FIG. 12  is a side elevational view of the outer structural tube of the multi-function deck tool of  FIG. 11  held vertically and the replaceable lifting fork component in place on the outer structural tube for use; 
           [0041]      FIG. 13A  is a top plan view of one size of replaceable lifting fork having the lifting arms spaced apart by the width of the lifting fork sleeve; 
           [0042]      FIG. 13B  is a top plan view of another size of replaceable lifting fork having the lifting arms spaced apart by a distance greater than the width of the lifting fork sleeve; 
           [0043]      FIG. 14A  is a side elevational view of the outer structural tube of the multi-function deck tool of the present invention having a lifting fork comprising a pair of pivotable lifting arms attached with individually pivotable lifting arms to enable the use of one or both lifting arms and enable the lifting arms to be pivoted up for storage, showing both pivotable arms pivoted down for use together; 
           [0044]      FIG. 14B  is a side elevational view of the outer structural tube of the multi-function deck tool of  FIG. 14A  showing one of the pivotable arms pivoted partially up and the other pivoted down. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0045]    In  FIGS. 1-9 , a multi-function deck tool  10  comprises an outer structural tube  20  having board lifting arms  21  to remove deck boards  71  from deck board support beams  70 , an inner structural tube or piston  30  riding on a threaded shaft  31  having a nail receiving slot  36  for removing nails  72  from the beams  70 , and an attachable aligning arm  50  for straightening, aligning, and holding new deck boards  71 B to nail the boards to the beams. 
         [0046]    In  FIGS. 1-9 , the outer structural tube  20  comprises a rigid elongated hollow structure having a bottom open end  29  and an aperture  25  in a top end  24 . A fork (also called rigid lifting arms)  21  extends down below the bottom open end  29  of the structural tube  20 , as shown in  FIG. 1 . The fork  21  comprises a pair of parallel L-shaped spaced rigid board lifting arms permanently attached to a lower portion of the outer structural tube  20 , extending below the bottom open end  29  and having two parallel lifting arms extending orthogonally relative to the outer structural tube  20  for lifting deck boards  71 , as shown in  FIGS. 2-4 . The rigid board lifting arms  21  are spaced a sufficient distance apart to straddle a deck board supporting beam  70 , as shown in  FIGS. 3 and 4 . 
         [0047]    In  FIG. 1 , an elongated threaded shaft  31  inside the inner structural tube  30  extends along the length of the outer structural tube  20 . The inner structural tube  30  comprises a threaded opening  35  in a top inner shaft end  37  to ride on the threaded portion  31  of the threaded shaft inside the inner structural tube  30 . A flat head  32  with a nail receiving slot  36  at the bottom end of the inner structural tube  30  pulls nails  72  from the deck board supporting beams  70  as shown in  FIGS. 5-7 . A drill bit engaging top portion  33  of the threaded shaft  31  extends out of the aperture  25  in the top end  24  of the outer structural tube  20  to be secured within a drill bit  61  of a drill  60  for rotating the threaded shaft reversibly by alternating the clockwise and counterclockwise rotation of the drill. A double thrust bearing  34 A and  34 B between the inner threaded portion  31  and the outer drill bit engaging portion  33  of the threaded shaft secures the threaded tube to the top end  24  of the outer structural tube  20  to permit rotation of the threaded shaft and prevent linear movement of the threaded shaft  31 . 
         [0048]    In  FIGS. 1-9 , the inner structural tube  30  comprises a rigid elongated hollow structure positioned slidably within the outer structural tube  20  between the threaded shaft  31  and the outer structural tube  20 . The inner structural tube  30  is preferably the same square or other rectangular cross sectional shape as the outer structural tube  20  and slightly smaller so that the inner structural tube  30  slides within the outer structural tube but cannot rotate relative to the outer structural tube  20 . The threaded opening  35  in the upper end  37  of the inner structural tube  20  engages the threaded shaft  31  so that rotation of the threaded shaft  31  causes linear movement of the inner tube  30  within the outer structural tube  20  along the threaded shaft  31  in one direction when the threaded shaft  31  is turned in a clockwise direction, and in an opposite direction when the threaded shaft  32  is turned in a counterclockwise direction. 
         [0049]    In  FIGS. 2-4 , the flat head  32  at the lower end of the inner structural tube  30  engages the top of a deck board supporting beam  70  with the rigid lifting arms  21  spanning the deck beam  70  and positioned under a deck board  71 . Activating the drill  60  in a direction to move the inner structural tube  30  downward causes the lifting arms  21  to lift the deck board  71  to remove it from the deck beam  70 , as shown in  FIG. 4 . 
         [0050]    In  FIGS. 5-7 , the inner structural tube  30  has at least one opening  38  (shown in  FIG. 6 ) in a side wall adjacent to the flat head  32 , with the flat head  32  having a nail receiving slot  36  (shown in  FIG. 1 ) that extends from the opening in the side wall opening inwardly to a mid portion of the flat head  32  to receive a deck nail shaft  72  therein by sliding the flat head along the beam  70  to engage the nail, as shown in  FIG. 5 . The head of the nail shaft  72  rests on the inner surface of the flat head  32  with the nail shaft extending downwardly out of the flat head  32  through the nail receiving slot  36 . In  FIG. 7 , the bottom of the lifting arms  21  rest transversely on a top surface of a deck beam  70  with the protruding deck nail  72  in the deck nail shaft. Activating the drill  60  attached to the drill bit end  33  of the inner structural tube  30  causes the inner structural tube  30  to rise up within the outer structural tube  20  to pull the deck nail  72  from the deck beam  70 , as shown in  FIG. 7 , thereby providing a multi-function deck tool  10  for removing both deck boards  71  and deck nails  72 . 
         [0051]    In  FIGS. 1 ,  8 , and  9 , the multi-function deck tool  10  further comprises an aligning arm  50  for use in combination with the multi-function deck tool  10  for straightening, aligning, and holding deck boards  71  for installation on the deck support beams  70 . The aligning arm comprising an elongated rigid shaft  52 , an attaching plate  53 , and an aligning plate  51 . The attaching plate  53  extends orthogonally from the rigid shaft  52  in a first direction at a first end of the rigid shaft  52 , with the attaching plate  53  having an opening therethrough for removably attaching the attaching plate  53  to the bottom face of the flat head  32  of the inner structural tube  30  with a fastener removably engaged in the nail receiving slot  36  and the elongated rigid shaft  52  extending along an outer surface of the outer structural tube  20 . The aligning plate  51  extends orthogonally from the rigid shaft  52  in a second opposite direction away from the rigid shaft  52  at a second end of the rigid shaft, the aligning plate  51  being positioned orthogonally to the outer structural tube  20  and parallel to the lifting arms  21 . After positioning the aligning plate  51  against an inner edge of a previously nailed secure deck board  71 A and hooking the lifting arms  21  over an outer edge of an unattached deck board  71 B, turning the drill  60  causes the outer structural tube  20  to move to draw in the lifting arms  21  and pull in the unattached deck board  71 B to straighten it and align it with the nailed secure deck board  71 A. With the drill  60  stopped and the aligning plate  51  and lifting arms  21  acting like a vise, the aligning arm  50  holds the unattached deck board  71 B in place in order to nail it to the deck support beams  70 . 
         [0052]    In  FIG. 10 , the elongated rigid shaft  52  has a width less that a space between the lifting arms  21  to fit between the lifting arms  21  and the aligning plate  51  has a width greater than the space between the lifting arms so the aligning plate  51  may be hooked facing up over the lifting arms  21  and the attaching plate  53  hooked facing down behind an attached nailed deck board  71 A adjacent to a building wall  80  with the multi-function deck tool  10  positioned with the outer structural tube  20  and drill oriented horizontally on a deck board support beam  70  so that the flat end  32  of the inner structural tube  30  presses against an unattached deck board  71 B straightening the unattached deck board and pushing it into alignment with the attached nailed deck board  71 A for attaching the unattached deck board  71 B to the deck board support beams  70 . 
         [0053]    In  FIG. 1 , the drill bit engaging top portion of the threaded shaft  33  may comprise a tapered end having three flattened sides for the jaws of the drill chuck  61  to grip better. 
         [0054]    In  FIG. 1 , the double thrust bearing  34 A and  34 B on the threaded shaft is held in place in the upper aperture  25  of the top end  24  of the outer structural tube  20  with a clip/pin  38  to facilitate disassembly for cleaning, lubricating, repairs, and to change the orientation of the inner parts, such as to face the nail shaft in a different direction. 
         [0055]    In FIGS.  1  and  5 - 7 , the flat head  32  comprises a nail shaft  36  without square or tapered edges and no sloping surfaces to insure that the nail head remains captured without slipping out. The nail shaft  36  also terminates with a curved radius and not a sharp V point, so the shaft of the nail  72  is surrounded by the end of the nail shaft  36  and not jammed into a sharp corner that the nail could get stuck in. No sharp edge is required on the nail puller  32  and  36 , as it is intended to place under nails that are already partially withdrawn. Nails pulled with this tool come out straight and are re-usable. 
         [0056]    In  FIGS. 1-9 , the parts that form the board lifting arms  21  at the bottom are made to a length to accommodate the most popular width of deck boards which are 5½″. 
         [0057]    In use, the drill  60  is attached to the drill bit engaging top  33  extending out of a proximal end of the multi-function deck tool. The drill bit engaging top  33  is an extension of the inner threaded shaft  31  inside the outer tube  20 . The drill  60  turns the drill bit engaging top  33  to turn the threaded shaft  31  and cause the inner structural tube  30  to move toward or away from the drill  60  depending on which direction the drill is turning. 
         [0058]    In  FIGS. 2-4 , for lifting deck boards  71 , the present invention board lifting tool uses the board lifting arms  21  built into the end of the outer tube  20  to lift nailed deck boards  71  from the deck board supporting beam  70 . With the inner structural tube  21  straddling the beam  70  and hooked under the board  71  and the bottom flat head  32  of the inner structural tube  30  resting on the beam  70 , turning the drill  60  causes the movement of the inner structural tube  30  away from the drill  60  so that the outer tube  20  and forks  21  move upward (since the beam  70  does not permit movement of the inner structural tube  30  resting against the beam  70 ) and the forks  21  lift the nailed board  71  to pull it up off of the deck board supporting beam  70  in order to remove the board. 
         [0059]    In  FIGS. 5-7 , the bottom flat head  32  with the nail receiving slot  36  built into the distal end of the inner structural tube  30  pulls nails from beams as the inner structural tube  32  rises within the outer tube  20 . The built-in nail puller hooks under a nail  72  protruding up from the beam  70  after ripping up the deck board  71 . With the inner structural tube  21  resting on the beam  70 , turning the drill  60  causes the movement of the inner piston  30  toward the drill  60  thereby pulling the nail  72  from the beam  70  so that the nail puller  32  moves upward, pulling the nail  72  from the beam  70 , as in  FIG. 7 . 
         [0060]    The board straightening and board aligning tool  50  with a wedge arm or aligning plate  51  is attached at one end of the multi-function deck tool, to the bottom flat head  32  built into the outer end of the inner structural tube  30 , so that with the aligning plate  51  positioned against a nailed deck board  71 A, the board lifting arms  21  at the end of the outer tube  20  move toward the board alignment plate  51  to draw in and straighten the loose board  71 B to align it with the last nailed board  71 A. The board lifting arms  21  moving back, along with the outer tube  20  and the drill  60 , pull back on the loose deck board  71 B while the aligning plate  51  stays in place on the nailed board  71 A. The aligning tool  50  also holds the loose board  71 B in place to nail it onto the beam  70 . 
         [0061]    In  FIGS. 11 ,  12 ,  13 A and  13 B, the lifting fork comprises a replaceable lifting fork  21 A having a lifting fork sleeve  14  for sliding down over the outer structural tube  20  and the outer structural tube further comprises a sleeve stop  13  adjacent to a bottom of the outer structural tube for engaging a stop plate  12  on the lifting fork sleeve  14  to hold the replaceable lifting fork in place for use, to enable replacement of the lifting fork with different lifting arm sizes and different spacing between the lifting arms to be used for different jobs. In  FIG. 13A , one size of replaceable lifting fork  21 A has the lifting arms spaced apart by the width of the lifting fork sleeve  14 . In  FIG. 13B , another size of replaceable lifting fork  21 A has the lifting arms  19 A and  19 B spaced apart by a distance greater than the width of the lifting fork sleeve  14 . 
         [0062]    In  FIGS. 14A and 14B  the lifting fork  21 B comprises a pair of pivotable lifting arms  19 A and  19 B attached to the outer structural tube  20  by attaching plates  18 A and  18 B each having a pivot pin  16  connecting it to the outer structural tube  20  and an arched slot  16  for engaging a protruding pin  15  from the outer structural tube  20  to enable the use of one lifting arm or both lifting arms and to enable the lifting arms to be pivoted up for storage. In  FIG. 14A , both pivotable lifting arms  19 A and  19 B are pivoted down for use together. In  FIG. 14B , one pivotable lifting arm  19 A is pivoted partially up and the other pivotable lifting arm  19 B is pivoted down. 
         [0063]    It is understood that the preceding description is given merely by way of illustration and not in limitation of the invention and that various modifications may be made thereto without departing from the spirit of the invention as claimed.

Technology Category: 7