U.S. patent application number 17/182694 was filed with the patent office on 2021-07-15 for modified drill guide system.
The applicant listed for this patent is Kreg Enterprises, Inc.. Invention is credited to Brian Hill.
Application Number | 20210213542 17/182694 |
Document ID | / |
Family ID | 1000005417750 |
Filed Date | 2021-07-15 |
United States Patent
Application |
20210213542 |
Kind Code |
A1 |
Hill; Brian |
July 15, 2021 |
MODIFIED DRILL GUIDE SYSTEM
Abstract
A pocket hole jig system is presented having a guide assembly
having a drilling face and a plurality of drill guides that
intersect with the drilling face. The main body of the guide
assembly is formed of a first material that is rigid and provides
structural integrity to the guide assembly. The first material has
a low coefficient of friction. A grip layer is placed on the
drilling face of the guide assembly. The grip layer is formed of a
softer material that has a higher coefficient of friction than the
material that forms the main body of the guide assembly. When
placed on a workpiece, the grip layer provides increased grip on
the workpiece thereby holding the workpiece and guide assembly in
place and requiring less clamping pressure to hold the workpiece
and guide assembly together.
Inventors: |
Hill; Brian; (Ames,
IA) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Kreg Enterprises, Inc. |
Huxley |
IA |
US |
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|
Family ID: |
1000005417750 |
Appl. No.: |
17/182694 |
Filed: |
February 23, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16180527 |
Nov 5, 2018 |
10967440 |
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17182694 |
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62583179 |
Nov 8, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B23B 2247/10 20130101;
B23B 2247/12 20130101; B23B 47/28 20130101 |
International
Class: |
B23B 47/28 20060101
B23B047/28 |
Claims
1. A pocket hole jig system, comprising: a main body; the main body
formed of a first material; the main body having a drilling face;
the main body having a first drill guide; wherein the first drill
guide has a bore that is aligned to intersect the drilling face at
an angle; a grip layer positioned on the drilling face of the main
body; the grip layer formed of a second material; wherein the
second material of the grip layer has a higher coefficient of
friction than the first material of the main body; wherein the grip
layer includes an aperture where a drill bit intersects the
drilling face of the main body; and wherein at least a portion of
the grip layer is flush with the drilling face; wherein when the
grip layer on the drilling face of the main body is placed on a
surface of a workpiece, the grip layer helps to hold the main body
in place on the workpiece so as to prevent movement during
drilling.
2. The system of claim 1 further comprising: the main body having a
lower wall; the main body having an upper wall; the main body
having opposing sidewalls; and the main body having a rear
wall.
3. The system of claim 1, wherein the first material of the main
body has a higher durometer than the second material of the grip
layer.
4. The system of claim 1, wherein the first material of the main
body is harder than second material of the grip layer.
5. The system of claim 1, wherein the grip layer covers the
drilling face.
6. The system of claim 1, wherein the grip layer covers a portion
of the drilling face.
7. The system of claim 1, wherein the grip layer protrudes forward
a distance from at least a portion of the drilling face.
8. The system of claim 1, further comprising an insert, wherein the
insert is positioned within the main body, wherein the insert is
formed of a metallic material.
9. The system of claim 1, wherein a portion of the drilling face is
formed of a forward side of an insert.
10. The system of claim 1, further comprising a second drill guide,
wherein the second drill guide has a bore that is aligned to
intersect with the drilling face at an angle.
11. The system of claim 1, wherein a clamp clamps the main body to
the workpiece.
12. The system of claim 1, wherein the aperture is a hole in the
grip layer.
13. The system of claim 1, wherein the aperture is oval shaped.
14. The system of claim 1, wherein the drilling face includes an
oval shaped aperture and the aperture in the grip layer is about
the same size as the oval shaped aperture in the drilling face.
15. The system of claim 1, wherein the aperture is a hole in the
grip layer that has an edge that surrounds the drill bit with close
tolerances when the drill bit extends through the aperture.
16. The system of claim 1, wherein the grip layer forms an extended
continuous surface on the drilling face.
17. The system of claim 1, wherein the grip layer is bonded with
the drilling face, wherein the bond between the grip layer and the
drilling face is characteristic of a bond between two materials
that are molded together.
18. A pocket hole jig system, comprising: a main body; the main
body having a drilling face; the main body having a first drill
guide; wherein the first drill guide has a bore that is aligned to
intersect the drilling face at an angle; a grip layer positioned on
the drilling face of the main body; wherein the grip layer is
formed of a material that is softer than and has a higher
coefficient of friction than the material that the main body is
formed of; wherein the grip layer is arranged above, below, and to
the sides of a drill bit that exits the first drill guide; wherein
the grip layer is compressible; wherein the grip layer is
configured and arranged to be flush with at least a portion of the
drilling face; and wherein when the grip layer on the drilling face
of the main body is placed on a surface of a workpiece, the grip
layer helps to hold the main body in place on the workpiece so as
to prevent movement during drilling.
19. The system of claim 18, wherein the grip layer covers the
drilling face.
20. The system of claim 18, wherein the grip layer covers a portion
of the drilling face.
21. The system of claim 18, wherein the grip layer protrudes
forward a distance from at least a portion of the drilling
face.
22. The system of claim 18, further comprising an insert, wherein
the insert is formed of a metallic material.
23. The system of claim 18, wherein a portion of the drilling face
is formed of a forward side of an insert.
24. The system of claim 18, further comprising a second drill
guide, wherein the second drill guide has a bore that is aligned to
intersect with the drilling face at an angle.
25. The system of claim 18, wherein a clamp clamps the main body to
the workpiece.
26. The system of claim 18, wherein the grip layer is bonded with
the drilling face, wherein the bond between the grip layer and the
drilling face is characteristic of a bond between two materials
that are molded together.
27. A pocket hole jig system, comprising: a main body; the main
body having a drilling face at a forward side; the main body having
a first drill guide therein; wherein the first drill guide has a
bore that is aligned to intersect with the drilling face at an
angle; the main body formed of a first material; a grip layer
positioned on the drilling face of the main body; wherein the grip
layer is formed of a second material; wherein the second material
of the grip layer has a higher coefficient of friction than the
first material of the main body; wherein the grip layer includes an
aperture where a drill bit intersects the drilling face of the main
body such that the grip layer surrounds the drill bit where the
drill bit intersects the drilling face; wherein the grip layer
covers at least a portion of the drilling face; wherein the grip
layer is flush with at least a portion of the drilling face;
wherein when the grip layer on the drilling face of the main body
is placed on a surface of a workpiece, the grip layer helps to hold
the main body in place on the workpiece so as to prevent movement
during drilling.
28. The system of claim 27 further comprising: the main body having
a lower wall; the main body having an upper wall; the main body
having opposing sidewalls; and the main body having a rear
wall.
29. The system of claim 27 further comprising: wherein at least a
portion of the drilling face is formed of a forward side of an
insert; wherein the insert is formed of a metallic material.
30. The system of claim 27, wherein the grip layer is bonded with
the drilling face, wherein the bond between the grip layer and the
drilling face is characteristic of a bond between two materials
that are molded together.
Description
CROSS REFERENCE TO RELATED PATENT APPLICATION
[0001] This application is a continuation of U.S. Utility
application Ser. No. 16/180,527, which was filed on Nov. 5, 2018,
which claims priority to U.S. Provisional Application 62/583,179
filed on Nov. 8, 2017, the entirety of which is fully incorporated
by reference herein.
FIELD OF THE DISCLOSURE
[0002] This disclosure relates generally to drilling jig systems
and, more particularly, and without limitation, to improved
drilling jig systems that have increased grip on workpieces.
BACKGROUND OF THE DISCLOSURE
[0003] Pocket hole wood joinery involves joining boards by
inserting a fastener at an angle through the edge of one workpiece
into an adjoining workpiece, thereby joining the two workpieces
together. Such joints are commonly used for face frames, cabinet
boxes, leg-to-rail joinery in chairs and tables, and so forth.
Drill guides or jigs are used to drill stepped holes through which
the fasteners or pocket screws are inserted into the adjoining
workpiece.
[0004] To facilitate the formation of pocket hole joinery,
Applicant, Kreg Tool Company offers a line of pocket hole jigs.
These pocket hole jigs clamp a workpiece in place and/or are
clamped to a workpiece and help guide a stepped drill bit at an
angle into the workpiece. The pocket hole formed by this process is
configured to receive a screw that is used to screw two workpieces
together.
[0005] Existing jigs for use forming pocket hole joinery are
generally formed of metallic materials or rigid plastic or
composite materials or a combination of metallic materials and
rigid plastic or composite materials. Using metallic materials and
rigid plastic or composite materials provides the benefits of
producing a jig that is rigid, durable and long lasting. However,
the use of these rigid materials has its drawbacks.
[0006] Namely, pocket hole jigs are generally used with rigid
workpieces, such as boards or sheets of wood or composite material.
When a pocket hole jig is formed of metallic materials and/or
plastic or composite materials there is a low coefficient of
friction between the workpiece and the pocket hole jig. This low
coefficient of friction between the workpiece and pocket hole jig
can lead to relative motion between the workpiece and the pocket
hole jig which is highly undesirable as this can lead to inaccurate
manufacture of parts or unnecessary scrap. In addition, movement of
the pocket hole jig during use can lead to injury. This is made
worse by the great amount of force that a user applies while
drilling a pocket hole jig in a workpiece.
[0007] To compensate for the low coefficient of friction between
the workpiece and the pocket hole jig, higher levels of clamping
force may be applied between the pocket hole jig and the workpiece.
This high clamping pressure can cause damage to the surfaces of the
workpiece, can damage the pocket hole jig, can reduce the useful
life of the pocket hole jig, can be exhausting to a user, and is
generally inconvenient and undesirable. These negative effects are
particularly exasperated when working with workpieces that have a
particularly low coefficient of friction such as coated materials,
finished workpieces, Formica, and the like.
[0008] One potential solution is to provide a roughened surface on
the pocket hole jig that engages the workpiece. While a roughened
surface may increase the coefficient of friction between the pocket
hole jig and the workpiece providing a roughened surface on the
pocket hole jig that engages the workpiece has deleterious effects
that are not acceptable. Namely, when a pocket hole jig has a
roughened surface on it and it is clamped into a workpiece, the
roughened surface makes an impression on the surface of workpiece.
This scarred surface is unacceptable in many applications,
especially applications where a workpiece with a finished surface
is being used. Another drawback to using a roughened surface is
that over time the roughened surface wears. As such, over time the
roughened surface has less and less grip on the workpiece. Another
drawback to using a roughened surface is that it has a tendency to
scratch the workpiece when inserting and removing the workpiece
from the jig. Another drawback to using a roughened surface is that
the roughened surface is undesirable to touch by a user.
[0009] For the reasons stated above, and for other reasons stated
below which will become apparent to those skilled in the art upon
reading and understanding the present disclosure, there is a need
in the art for an improved pocket hole jig that provides increased
grip on a workpiece.
[0010] Thus it is an object of at least one embodiment of the
disclosure to provide a pocket hole jig system that improves upon
the state of the art.
[0011] Another object of at least one embodiment of the disclosure
to provide a pocket hole jig system that is easy to use.
[0012] Yet another object of at least one embodiment of the
disclosure to provide a pocket hole jig system that is
efficient.
[0013] Another object of at least one embodiment of the disclosure
to provide a pocket hole jig system that can be used with any type
of workpiece.
[0014] Yet another object of at least one embodiment of the
disclosure to provide a pocket hole jig system that is cost
effective.
[0015] Another object of at least one embodiment of the disclosure
to provide a pocket hole jig system that forms accurate pocket
holes.
[0016] Yet another object of at least one embodiment of the
disclosure to provide a pocket hole jig system that is safe to
use.
[0017] Another object of at least one embodiment of the disclosure
to provide a pocket hole jig system that has a durable design.
[0018] Yet another object of at least one embodiment of the
disclosure to provide a pocket hole jig system that has a long
useful life.
[0019] Another object of at least one embodiment of the disclosure
to provide a pocket hole jig system that provides additional
functionality for pocket hole jigs and pocket hole joinery.
[0020] Yet another object of at least one embodiment of the
disclosure to provide a pocket hole jig system that has a wide
variety of uses.
[0021] Another object of at least one embodiment of the disclosure
to provide a pocket hole jig system that has a wide variety of
applications.
[0022] Yet another object of at least one embodiment of the
disclosure to provide a pocket hole jig system that provides cost
savings to a user.
[0023] Another object of at least one embodiment of the disclosure
to provide a pocket hole jig system that is relatively
inexpensive.
[0024] Yet another object of at least one embodiment of the
disclosure to provide a pocket hole jig system that provides
value.
[0025] Another object of at least one embodiment of the disclosure
to provide a pocket hole jig system that is interchangeable with
existing Kreg pocket hole jigs.
[0026] Yet another object of at least one embodiment of the
disclosure to provide a pocket hole jig system that facilitates the
formation of aesthetically pleasing finished products.
[0027] Another object of at least one embodiment of the disclosure
to provide a pocket hole jig system that provides an increased
coefficient of friction on a workpiece.
[0028] Yet another object of at least one embodiment of the
disclosure to provide a pocket hole jig system that prevents or
reduces relative movement between the pocket hole jig and the
workpiece.
[0029] Another object of at least one embodiment of the disclosure
to provide a pocket hole jig system that reduces the amount of
clamping pressure required to adequately clamp a pocket hole jig to
a workpiece.
[0030] Yet another object of at least one embodiment of the
disclosure to provide a pocket hole jig system that does not damage
a workpiece when clamped.
[0031] Another object of at least one embodiment of the disclosure
to provide a pocket hole jig system that can be used with any type
of pocket hole jig.
[0032] These and other objects, features, or advantages of at least
one embodiment will become apparent from the specification, figures
and claims.
BRIEF SUMMARY OF DISCLOSURE
[0033] A pocket hole jig system is presented having a guide
assembly having a drilling face and a plurality of drill guides
that intersect with the drilling face. The main body of the guide
assembly is formed of a first material that is rigid and provides
structural integrity to the guide assembly. The first material has
a low coefficient of friction. A grip layer is placed on the
drilling face of the guide assembly. The grip layer is formed of a
softer material that has a higher coefficient of friction than the
material that forms the main body of the guide assembly. When
placed on a workpiece, the grip layer provides increased grip on
the workpiece thereby holding the workpiece and guide assembly in
place and requiring less clamping pressure to hold the workpiece
and guide assembly together.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a side elevation view of a pocket hole jig system,
the view showing a base having a lower portion and an upright
portion, the view showing a guide assembly attached to the upright
portion of the base, the view showing a pair of drill bits
extending through the guide assembly at an angle with the lower
ends of the drill bits protruding out of the drilling face of the
guide assembly slightly, the view showing a dust collector system
attached to the rear side of the upright portion which is
configured to facilitate removal of dust and debris, the view
showing a clamping assembly attached to the lower portion of the
base on a side opposite the upright portion of the base and the
guide assembly, the view showing the clamping assembly in a forward
or clamped position, the view does not show a workpiece clamped
between the drilling face of the guide assembly and the plunger pad
of the clamping assembly, the view showing grip layer on the
drilling face of the guide assembly, on the upper surface of the
lower portion of the base and on the face of the plunger pad of the
clamping assembly;
[0035] FIG. 2 is a top elevation view of the pocket hole jig system
shown in FIG. 1;
[0036] FIG. 3 is a perspective view of the pocket hole jig system
shown in FIGS. 1 and 2;
[0037] FIG. 4 is a front elevation view of the guide assembly shown
in FIGS. 1-3 the view showing grip layer on the drilling face of
the guide assembly;
[0038] FIG. 5 is a rear elevation view of the guide assembly shown
in FIGS. 1-4;
[0039] FIG. 6 is a left side elevation view of the guide assembly
shown in FIGS. 1-5;
[0040] FIG. 7 is a right side elevation view of the guide assembly
shown in FIGS. 1-6;
[0041] FIG. 8 is a top side elevation view of the guide assembly
shown in FIGS. 1-7;
[0042] FIG. 9 is a bottom side elevation view of the guide assembly
shown in FIGS. 1-8;
[0043] FIG. 10 is a top front perspective view of the guide
assembly shown in FIGS. 1-9;
[0044] FIG. 11 is a top rear perspective view of the guide assembly
shown in FIGS. 1-10;
[0045] FIG. 12 is a bottom front perspective view of the guide
assembly shown in FIGS. 1-11;
[0046] FIG. 13 is a bottom rear perspective view of the guide
assembly shown in FIGS. 1-12;
[0047] FIG. 14 is a front elevation view of the guide assembly
shown in FIGS. 1-13 shown held in a portable base having lip
positioned at its lower end;
[0048] FIG. 15 is a rear elevation view of the guide assembly shown
in FIGS. 1-14 shown held in a portable base;
[0049] FIG. 16 is a left side elevation view of the guide assembly
shown in FIGS. 1-15 shown held in a portable base having lip
positioned at its lower end;
[0050] FIG. 17 is a right side elevation view of the guide assembly
shown in FIGS. 1-16 shown held in a portable base having lip
positioned at its lower end;
[0051] FIG. 18 is a top side elevation view of the guide assembly
shown in FIGS. 1-17 shown held in a portable base having lip
positioned at its lower end;
[0052] FIG. 19 is a bottom side elevation view of the guide
assembly shown in FIGS. 1-18 shown held in a portable base having
lip positioned at its lower end;
[0053] FIG. 20 is a front top perspective view of the guide
assembly shown in FIGS. 1-19 shown held in a portable base having
lip positioned at its lower end;
[0054] FIG. 21 is a rear bottom perspective view of the guide
assembly shown in FIGS. 1-20 shown held in a portable base having
lip positioned at its lower end;
[0055] FIG. 22 is a top elevation view of a mini guide assembly
having only a single drill guide;
[0056] FIG. 23 is a bottom elevation view of a mini guide assembly
having only a single drill guide shown in FIG. 22, the view showing
a grip layer on the drilling face of the guide assembly;
[0057] FIG. 24 is a side elevation view of a mini guide assembly
having only a single drill guide shown in FIG. 22-23, the view
showing a grip layer on the drilling face of the guide
assembly;
[0058] FIG. 25 is a front elevation view of a mini guide assembly
having only a single drill guide shown in FIG. 22-24, the view
showing a grip layer on the drilling face of the guide
assembly;
[0059] FIG. 26 is a rear elevation view of a mini guide assembly
having only a single drill guide shown in FIG. 22-25, the view
showing a grip layer on the drilling face of the guide
assembly;
[0060] FIG. 27 is a rear top perspective view of a mini guide
assembly having only a single drill guide shown in FIG. 22-26, the
view showing a grip layer on the drilling face of the guide
assembly;
[0061] FIG. 28 is another rear top perspective view of a mini guide
assembly having only a single drill guide shown in FIG. 22-27, the
view showing a grip layer on the drilling face of the guide
assembly;
[0062] FIG. 29 is rear bottom perspective view of a mini guide
assembly having only a single drill guide shown in FIG. 22-28, the
view showing a grip layer on the drilling face of the guide
assembly;
[0063] FIG. 30 is another rear bottom perspective view of a mini
guide assembly having only a single drill guide shown in FIG.
22-29, the view showing a grip layer on the drilling face of the
guide assembly;
[0064] FIG. 31 is a top elevation view of a guide assembly having a
pair of drill guides and an attachment member on its top side and a
pair of alignment members having a lip connected adjacent its
sides;
[0065] FIG. 32 is a bottom elevation view of a guide assembly shown
in FIG. 31 having a pair of drill guides and an attachment member
on its top side and a pair of alignment members having a lip
connected adjacent its sides, the view showing a grip layer on the
drilling face of the guide assembly, the view showing a grip layer
on the drilling face of the guide assembly, the lower surface of
the alignment members and the forward face of the lips;
[0066] FIG. 33 is a right side elevation view of a guide assembly
shown in FIGS. 31-32;
[0067] FIG. 34 is a front side elevation view of a guide assembly
shown in FIGS. 31-33;
[0068] FIG. 35 is a rear side elevation view of a guide assembly
shown in FIGS. 31-34;
[0069] FIG. 36 is a left side elevation view of a guide assembly
shown in FIGS. 31-35;
[0070] FIG. 37 is a rear perspective view of a guide assembly shown
in FIGS. 31-36;
[0071] FIG. 38 is a front bottom perspective view of a guide
assembly shown in FIGS. 31-37;
[0072] FIG. 39 is a perspective view of guide assembly 18, shown in
FIGS. 1-21 in place within the portable base shown in FIGS. 14-21
clamped in place on a workpiece using a clamp, the view showing the
grip layer of the drilling face of the guide assembly in contact
with the surface of the workpiece, the view showing the grip layer
of the forward wall of the portable base in contact with the
surface of the workpiece, and the view showing the grip layer of
the upper surface of the lip of the portable base in contact with
the surface of the workpiece;
[0073] FIG. 40 is a perspective view of guide assembly 18, shown in
FIGS. 31-38 clamped in place on a workpiece using a clamp, the view
showing the grip layer of the drilling face of the guide assembly
in contact with the surface of the workpiece, the view showing the
grip layer of the forward wall of the alignment members in contact
with the surface of the workpiece, and the view showing the grip
layer of the upper surface of the lip of the alignment members in
contact with the surface of the workpiece;
[0074] FIG. 41 is another perspective view of guide assembly 18,
shown in FIGS. 31-38 clamped in place on a workpiece using a clamp,
the view showing the grip layer of the drilling face of the guide
assembly in contact with the surface of the workpiece, the view
showing the grip layer of the forward wall of the alignment members
in contact with the surface of the workpiece, and the view showing
the grip layer of the upper surface of the lip of the alignment
members in contact with the surface of the workpiece;
[0075] FIG. 42 is another perspective view of guide assembly 18,
shown in FIGS. 22-30 clamped in place on a workpiece using a clamp,
the view showing the grip layer of the drilling face of the guide
assembly in contact with the surface of the workpiece.
DETAILED DESCRIPTION
[0076] In the following detailed description of the embodiments,
reference is made to the accompanying drawings which form a part
hereof, and in which is shown by way of illustration specific
embodiments in which the invention may be practiced. These
embodiments are described in sufficient detail to enable those
skilled in the art to practice the invention, and it is to be
understood that other embodiments may be utilized and that
mechanical, procedural, and other changes may be made without
departing from the spirit and scope of the disclosure. The
following detailed description is, therefore, not to be taken in a
limiting sense, and the scope of the disclosure is defined only by
the appended claims, along with the full scope of equivalents to
which such claims are entitled.
[0077] As used herein, the terminology such as vertical,
horizontal, top, bottom, front, back, end and sides are referenced
according to the views presented. It should be understood, however,
that the terms are used only for purposes of description, and are
not intended to be used as limitations. Accordingly, orientation of
an object or a combination of objects may change without departing
from the scope of the disclosure.
[0078] System:
[0079] Pocket hole jig system 10 (or simply "system 10") is
presented. Pocket hole jig system 10 is formed of any suitable
size, shape and design and is configured facilitate the cutting of
pocket holes in a workpiece. In the arrangement shown, as one
example, with reference to FIGS. 1-3, pocket hole jig system 10
includes a base 12 having an L-shape when viewed from the side. The
L-shaped base 12 includes a lower portion 14 that extends in a
generally planar and horizontal manner, and an upright portion 16
that extends in a generally vertical manner with respect to the
lower portion 14. System 10 includes a guide assembly 18 having a
drilling face 20 and a plurality of drilling guides 22 therein. A
clamping assembly 24 is connected to base 12 that is configured to
clamp a workpiece 26 against or adjacent to the drilling face 20 of
the drill guide 18. A dust collector unit 28 is connected to the
upright portion 16 of base 12. A plurality of pocket hole drill
bits 30 are used in association with the system to form pocket
holes of various sizes in workpiece 26.
[0080] Base:
[0081] In the arrangement shown, as one example, with reference to
FIGS. 1-3, system 10 includes a base 12. Base 12 is formed of any
suitable size, shape and design and is configured to hold and
support workpiece 26 as pocket holes are cut out of workpiece 26.
In one arrangement, as is shown, as one example, with reference to
FIGS. 1-3, base 12 has an L-shape when viewed from the side. The
L-shaped base 12 includes a lower portion 14 that extends in a
generally planar and horizontal manner, and an upright portion 16
that extends in a generally vertical manner with respect to the
lower portion 14. In the arrangement shown, upright portion 16
extends upward from the lower portion 14 in a generally
perpendicular manner. In this way, the lower portion 14 and upright
portion 16 form a generally perpendicular arrangement or a right
angle corner there between. In the arrangement shown, as one
example, the lower portion 14 and upright portion 16 are formed of
a single monolithic member which may be formed by molding,
machining, casting or any other manufacturing process.
[0082] Lower portion 14 of base 12 is formed of any suitable size
shape and design. In the arrangement shown, as one example, when
viewed from above or below, the lower portion of base 12 has a
generally square or rectangular peripheral shape formed by the
intersection of opposing sidewalls 34 with opposing end walls 36.
In the arrangement shown, sidewalls 34 intersect with end walls 36
in a generally perpendicular manner, thereby forming a generally
square or rectangular shaped lower portion 14. In the arrangement
shown, sidewalls 34 and end walls 36 are generally flat and
straight. In one arrangement, sidewalls 34 and end walls 36 taper
or angle slightly outward as they extend downward from an upper
surface 38 to a bottom surface 40 so as to facilitate a more-sable
stance as well as to facilitate mold removal. However any other
shape is hereby contemplated for use.
[0083] Similarly, when viewed from the side, the lower portion 14
of base 12 extends between an opposing upper surface 38 and bottom
surface 40. In the arrangement shown, as one example, upper surface
38 and bottom surface 40 form a generally planar surface, or plane,
when viewed from the side. The generally planar surface formed by
the bottom surface 40 facilitates generally flat and stable
placemen of base 12 on a benchtop or other work surface. The
generally planar surface formed by the upper surface 38 facilitates
generally flat and stable placement of workpiece 26 on base 12 so
as to facilitate accurate cutting of pocket hole plugs 32. However
any other shape is hereby contemplated for use.
[0084] In one arrangement, as is shown, lower portion 14 of base 12
includes a plurality of openings 42 that are sized and shaped to
receive fasteners, such as screws or bolts, therein so as to
facilitate connection of base 12 to a benchtop or other work
surface so as to hold system 10 in place. In the arrangement shown,
one opening 42 is placed in each corner of the lower portion 14 of
base 12.
[0085] Also, in one arrangement, as is shown, the upper surface 38
of lower portion 14 includes drill bit recesses 44 and associated
indicia 46. Drill bit recesses 44 are semi-circular recesses in the
upper surface 38 of lower portion 14 that are sized and shaped to
receive a drill bit 30 therein. Indicia 46 are measurement markings
that correspond and identify positions along the length of the
drill bit recesses 44. Drill bit recesses 44 are configured to
receive a drill bit 30 therein and the indicia 46 are intended to
help set a desired depth of a stop collar on the drill bit 30 based
on the thickness of the workpiece 26 that is being used.
[0086] In one arrangement, as is shown, upright portion 16 is
positioned adjacent one end of lower portion 14, opposite the
clamping assembly 24, and extends upward therefrom. Upright portion
16 is formed of any suitable size, shape and design and is
configured to hold and slidably receive guide assembly 18 therein.
In one arrangement, as is shown, upright portion 16 includes
sidewalls 34 that are in generally flush alignment with the
sidewalls 34 of lower portion 14. Or, said another way, the
exterior surface of the sides of upright portion 16 extend upward
from the sidewalls 34 of lower portion 14 in a generally flush and
seamless manner. Upright portion 16 includes a rear wall 48, a
forward wall 50 and an upper wall 52.
[0087] In one arrangement, as is shown when viewed from the side,
rear wall 48 connects at its lower end to the upper end of the end
wall 36 of lower portion 14. In the arrangement shown, rear wall 48
curves as it extends forward and upward from the end wall 36 of
lower portion 14 before connecting to upper wall 52. Upper wall 52
connects at its rear side to the upper end of rear wall 48. Upper
wall 52 extends forward from rear wall 48 before connecting to
forward wall 50. In the arrangement shown, upper wall 52
establishes a plane that extends in approximate parallel spaced
alignment to the plane established by the upper surface 38 of the
lower portion 14 of base 12. Forward wall 50 connects at its lower
end to the upper surface 38 of the lower portion 14 of base 12 and
extends upwardly therefrom before connecting to the forward end of
upper wall 52. In the arrangement shown, forward wall 50
establishes a plane that extends in approximate perpendicular
alignment to the plane established by the upper surface 38 of the
lower portion 14 of base 12.
[0088] In the arrangement shown, as one example, the upper end of
upright portion 16 includes an opening 54. Opening 54 is sized and
shaped to receive guide assembly 18 therein with close and tight
tolerances while allowing for sliding vertical movement of guide
assembly 18 within upright portion 16. In the arrangement shown, as
one example, when viewed from above, opening 54 is generally
C-shaped such that the opening 54 captures guide assembly 18
therein and prevents guide assembly 18 from escaping the open
forward side of opening 54. When guide assembly 18 is placed within
opening 54, guide assembly 18 is vertically adjustable within
upright portion 16. This vertical adjustment allows the height of
guide assembly 18 to be positioned at any desired location within
the range of upright portion 16 so as to facilitate drilling pocket
holes in workpieces 26 of various thickness.
[0089] Guide assembly 18 is infinitely adjustable within upright
portion 16. Guide assembly 18 is also adjustable to pre-determined
positons. In the arrangement shown, the rear side of upright
portion 16 includes a set pin 56 that extends through upright
portion 16 and into opening 54. As set pin 56 extends into opening
54, set pin 56 engages a rear wall 58 of the guide assembly 18
thereby locking the position of guide assembly 18 in place. In one
arrangement, guide assembly 18 includes one or more set openings 60
in its rear wall 58 that receive set pin 56 at predetermined
positions. Any number of openings 60, and therefor any number of
predetermined positions that correspond to common workpiece
thicknesses, are hereby contemplated for use in the rear wall 58 of
guide assembly 58.
[0090] In the arrangement shown, as one example, when guide
assembly 18 is received within opening 54 of upright portion 16 of
base 12, the forward wall, or drilling face 20 of guide assembly 18
is positioned a distance in front of the forward wall 50 of upright
portion 16. In this arrangement, the plane established by drilling
face 20 of guide assembly 18 is positioned in approximate parallel
spaced alignment with the plane established by the forward wall 50
of upright portion 16. This alignment ensures that the drilling
face 20 of guide assembly 18 engages a surface of workpiece 26 in
flat and flush engagement without interference from upright portion
16. In another arrangement the planes of drilling face 20 of guide
assembly 18 and the forward wall 50 of upright portion 16 are
positioned in approximate parallel planar alignment.
[0091] In one arrangement, the rear side of upright portion 16
includes one or more exit holes 64 (not shown in detail as they are
covered by dust collector unit 28, but they are shown in detail in
Applicants U.S. Pat. No. 8,231,313, which is incorporated fully by
reference herein). Exit holes 64 are positioned in the rear wall 48
of upright portion 16, adjacent where the rear wall 58 of guide
assembly 18 is located when guide assembly 18 is located within
upright portion 18. Exit holes 64 in rear wall 48 of upright
portion 16 align with or are in communication with exit holes 66 in
the rear wall 58 of guide assembly 18. Exit holes 64 in upright
portion 16 extend an elongated vertical distance. This vertical
length of exit holes 64 allows drilled material, such as wood
chips, dust and debris generated during drilling to exit the guide
assembly through exit holes 66 and exit the upright portion 16
through exit holes 64 regardless of the vertical position of guide
assembly 18 within upright portion 16. That is, by having exit
holes 64 be vertically stretched a distance, this ensures that the
exit holes 64, 66 are in overlapping communication with one another
regardless of where guide assembly 18 is positioned within upright
portion 16. This ensures proper removal of drilled material, such
as wood chips, dust and debris, regardless of the position of the
guide assembly 18 within upright portion 16. In addition, by having
the exit holes 66 in rear wall 58 of guide assembly 18 be
vertically elongated, this ensures that drilled material, such as
wood chips, dust and debris is properly removed regardless of the
position of the drill bit 30 within the guide assembly 18 and/or
drill guide 22. Quick removal of drilled material facilitates high
quality cuts and high quality and dimensionally accurate pocket
holes as well as easier drilling.
[0092] In one arrangement, base 12 is a Kreg K3, Kreg K4, Kreg K5
or other Kreg pocket hole jig commercially available on the market
and guide assembly 18 is interchangeable with these existing
products.
[0093] Dust Collection Unit:
[0094] In the arrangement shown, system 10 includes a dust
collection unit 28. Dust collection unit 28 is formed of any
suitable size, shape and design and is configured to connect to
base 12, or more specifically the rear wall 48 of upright portion
14 to facilitate the removal of drilled material such as wood
chips, dust and debris. In one arrangement, as is shown, dust
collection unit 28 includes a main body 68 and a snout 70.
[0095] Main body 68 is formed of any suitable size, shape and
design and is configured to connect to the rear wall 48 of upright
portion 16. In the arrangement shown, as one example, main body 68
is generally square or rectangular in shape and fits within a
correspondingly sized recess within the rear wall 48 of upright
portion 16 such that the two components frictionally engage and
hold on to one another. In the arrangement shown, the upper end of
main body 68 includes a recess therein that provides clearance for
set pin 56.
[0096] Snout 70 is formed of any suitable size, shape and design
and is configured to connect main body 68 to a vacuum hose to
facilitate removal of drilled material captured by main body 68. In
the arrangement shown, as one example, snout 70 is a generally
tubular shaped member that connects to main body 68 and extends
outwardly therefrom. In one arrangement, snout 70 is fixed with
respect to main body 68, whereas in another arrangement, the
position of snout 70 is adjustable with respect to main body
68.
[0097] When a vacuum hose is connected to snout 70 and main body 68
is connected to the rear wall 48 of upright portion 16 of base 12
and a pocket hole is drilled using a drill bit 30 extending through
a drill guide 22 of the guide assembly 18 drilled material, such as
wood chips, dust and debris passes through the exit hole 66 in the
rear wall 58 of guide assembly 18. This drilled material then
passes through the aligned exit hole 66 in the rear wall 48 of
upper portion 16 of base 12 and into main body 68 of dust collector
unit 28. This drilled material is then pulled through snout 70 of
dust collector unit 28 by vacuum. In this way, the combination of
the aligned exit holes 64, 66 in upright portion 16 and guide
assembly 18 and the connection of the dust collector unit 28
facilitates the quick, efficient and easy removal of drilled
material from the drill guides 22 thereby providing a
cleaner-operating system 10, as well as producing high quality cuts
as the drilled material is not allowed to interfere with the
drilling operation as it is quickly removed along the length of the
cutting operation.
[0098] Clamp Assembly:
[0099] In the arrangement shown, system 10 includes a clamping
assembly 24. Clamping assembly 24 is formed of any suitable size,
shape and design and is configured to clamp workpiece 26 against
the drilling face 20 of guide assembly 18. In one arrangement, as
is shown, clamping assembly 24 is connected to the lower portion 14
of base 12 opposite the upright portion 16 of base 12. In the
arrangement shown, as one example, clamping assembly 24 includes a
handle assembly 72 that is configured to be grasped by a user to
manipulate operation of the clamping assembly 24. The lower end of
handle assembly 72 connects at a first pivot point 74 to a mounting
member 76.
[0100] Mounting member 76 includes a base plate 78 that extends in
a generally planar manner and is configured to sit upon and engage
the upper surface 38 of lower portion 14 of base 12. In this way,
base plate connects clamping assembly 24 to base 12 and provides
stability to clamping assembly 24. In the arrangement shown, base
plate 78 is connected to and held to lower portion 14 of base 12 by
a plurality of fasteners 80 that extend through openings in base
plate 78 and into the material of the lower portion 14 of base
12.
[0101] A rear tab 82 extends upward from base plate 78 adjacent its
outward end and receives the lower end of handle assembly 72 and
first pivot point 74. A center tab 84 is positioned a distance
inward from rear tab 82. Center tab 84 extends upward from base
plate 78 a distance and terminates in an upper surface that
establishes a stop surface when clamping assembly 24 is in a fully
clamped position, which also corresponds with the clamping assembly
24 being in a slightly over-center position which helps to hold the
clamping assembly 24 in a fully clamped position. A forward tab 86
is positioned a distance inward from center tab 84. Forward tab 86
extends upward from base plate 78 a distance and terminates in a
guide collar 88 that slidably holds and guides shaft 90. Guide
collar 88 allows shaft 90 to slide through guide collar 88 between
a fully clamped position and a fully open position. In the
arrangement shown, rear tab 82, center tab 84 and forward tab 86
are generally centrally positioned upon base plate 78 thereby
providing balance and stability to clamping assembly 24.
[0102] Handle assembly 72 also connects to a first linkage member
92 at a second pivot point 94. First linkage member 92 connects at
its rearward end to handle assembly 72. First linkage member 92
connects at its forward end to the rearward end of shaft 90 at
third pivot point 96.
[0103] The forward end of shaft 90 threadably receives threaded
shaft 98. Threaded shaft 98 threads in and out of shaft 90 thereby
adjusting the length threaded shaft 98 extends outward from shaft
90. Threaded shaft 98 includes a nut 100 thereon that is used to
set the depth of threaded shaft 98 upon shaft 90. A plunger pad 102
is connected to the inward most end of threaded shaft 98 and has an
extended forward surface area that engages the workpiece 26,
thereby spreading out the clamping forces and preventing the
potential for marking of the workpiece 26.
[0104] The clamping assembly 24 shown and described herein is just
one of countless examples. Any other form of a clamping assembly or
clamping mechanism is hereby contemplated for use. This includes a
ratcheting-type clamping assembly as is shown in Applicant's
pending U.S. patent application Ser. No. 14/275,402, which is fully
incorporated by reference herein; this also includes the same-side
clamping assembly as is shown in Applicant's issued U.S. Pat. No.
8,231,313, which is fully incorporated by reference herein; this
also includes any electric, pneumatic, hydraulic or other powered
clamping assemblies; this also includes any hand-clamp assemblies,
as is shown in Applicant's U.S. patent application Ser. No.
15/188,151, which is fully incorporated by reference herein.
[0105] Guide Assembly:
[0106] In the arrangement shown, as one example, system 10 includes
a guide assembly 18, which is shown in particular in FIGS. 4-14.
Guide assembly 18 is formed of any suitable size, shape and design
and is configured to facilitate the cutting of pocket holes in
workpiece 26. In one arrangement, as one example, with reference to
FIGS. 1-3, guide assembly 18 is intended to be used when connected
to base 12 by sliding within opening 54 in upright portion 16 and
facilitates guiding drill bits 30 at an angle through drilling face
20 and into workpiece 26 to form pocket holes. In another
arrangement, guide assembly 18 is intended to be used in a
standalone manner where guide assembly 18 is clamped directly
against a workpiece 26. In another arrangement, as one example,
with reference to FIGS. 15-21, guide assembly 18 is configured to
be used in a portable guide 200.
[0107] In one arrangement, as is shown, as one example, with
reference to FIGS. 4-14, guide assembly 18 is formed of a generally
square or rectangular shape extending vertically a distance from a
lower end 104 to an upper end 106; and extending a width between
opposing sidewalls 108; and extending a thickness between forward
face, or drilling face 20 and rear wall 58.
[0108] In the arrangement shown, the lower end 104 of guide
assembly 18 and the upper end 106 of guide assembly 18 are
positioned at an angle to one another. That is, in the arrangement
shown, when guide assembly 18 is in place within opening 54 of
upright portion 16, the plane established by the lower end 104 of
guide assembly 18 is in approximate parallel alignment to the plane
established by the upper surface 38 of lower portion 14 of base 12.
In contrast, the plane established by the upper end 106 of guide
assembly is not in approximate parallel alignment to the plane
established by the upper surface 38 of lower portion 14 of base 12.
In contrast, the plane established by the upper end 106 of guide
assembly 18 is positioned at an angle to the plane established by
the lower end 104 of guide assembly 18. In one arrangement, this
angle is approximately 15 degrees, however any other angle is
hereby contemplated from 1 degree to 89 degrees. In the arrangement
shown, the angle established by the plane formed by the upper end
106 of guide assembly 18 is approximately the same angle that the
bore of drill guides 22 held within guide assembly 18 exit the
drilling face 20. This angle also corresponds to the angle of the
pocket hole formed by the system 10 in workpiece 26. In the
arrangement shown, the generally planar surface of the upper end
106 of guide assembly 18 extends in approximate perpendicular
alignment to the center axis of the bores of drill guides 22.
[0109] In the arrangement shown, sidewalls 108 of guide assembly 18
extend in approximate parallel spaced alignment to one another.
Sidewalls 108 connect at their lower end to lower end 104 of guide
assembly 18 in approximate perpendicular alignment. Sidewalls 108
connect at their upper end to upper end 106 of guide assembly 18 in
approximate perpendicular alignment. The width of guide assembly 18
between opposing sidewalls 108 is sized and shaped to fit within
the opening 54 in upright portion 16 of base 12 within close
tolerances.
[0110] To facilitate connection to opening 54 in upright portion 16
of base 12, sidewalls 108 include a step 110 therein at their
forward end. Step 110 steps in the width of guide assembly 18
adjacent the forward face of drilling face 20 and makes room for
the inward extension of forward wall 50 of upright portion 16. Step
110 causes the forward face or drilling face 20 to be slightly
narrower in width than at the rear wall 58. The distance between
the stepped portion of guide assembly 18 is approximately the
distance between the inward edges of the opposing forward walls 50
of upright portion 16. Said another way, the steps 110 allow the
drilling face 20 to extend through the slot in the upright portion
16 of base 12 so as to ensure that the drilling face 20 of guide
assembly 18 engages the workpiece 26 prior to the forward wall 50
of upright portion 16.
[0111] Guide assembly 18 includes one or more drill guides 22
therein. Drill guides 22 are formed of any suitable size, shape and
design and are configured to guide drill bits 30 at a precise
angle. In one arrangement, to provide increased durability and wear
resistance, drill guides 22 are formed of a hardened metallic
material, whereas other portions of the drill guide 22 are formed
of a plastic material or composite material, or non-metallic
material, so as to reduce weight and manufacturing cost while
providing a pleasing aesthetic appeal and comfortable use.
[0112] In the arrangement shown, a three drill guides 22 are
present within guide assembly 18. However any other number of drill
guides 22 are hereby contemplated for use including one, two,
three, four, five or more.
[0113] Similarly, in the arrangement shown, where three drill
guides 22 are present within guide assembly 18, the drill guides 22
are of the same size. In other arrangements, one drill guide 22 is
larger than the other drill guide 22 thereby facilitating the
formation of different sized pocket holes. In this arrangement, the
larger drill guide 22 is configured to receive what is known as a
HD or Heavy Duty drill bit 30 that is configured to be used in
association with thicker workpieces 26, such as 2.times.4's and
2.times.6's and the like. In this arrangement, the smaller drill
guide 22 is configured to receive what is known as a standard drill
bit 30 that is configured to be used in association with thinner
workpieces 26, such as 1 inch thick and smaller workpieces 26. A
third or micro sized drill bit 30 and drill guide 22 is
contemplated for use with thinner workpieces 26. The arrangement
where multiple drill guides 22 are the same size facilitate
multiple pocket holes without having to move the drill guide 22 or
workpiece 26. Alternatively, the use of multiple sizes of drill
guides 22 allows the use of a single drill guide 22 for multiple
workpiece thicknesses. In the arrangement shown, where three drill
guides 22 are used, two drill guides 22 are positioned in close
spaced relation whereas the third drill guide 22 is spaced a
greater distance away from the other two drill guides 22. This
varied spacing provides a great amount of variability and a number
of combinations of spacing between pocket holes without having to
move the drill guide 18 relative to workpiece 26.
[0114] In the arrangement shown, as one example, drill guides 22
extend though guide assembly 18 in approximately perpendicular
alignment to the plane established by the upper end 106 of guide
assembly 18. As such, drill guides 22 intersect the drilling face
20 at a corresponding angle to the intersection of the plane
established by the upper end 106 of guide assembly 18 and the
drilling face 20 of guide assembly 18. The drill guides 22 drill
bit 30 at this precise angle during the drilling operation.
[0115] In the arrangement shown, due to the angle of the
intersection between the drill guides 22 and the drilling face 20,
the drill guides 22 form an oval shaped opening in the drilling
face 20 of guide assembly 18. In one arrangement, to reduce
chipping of workpiece 26 around the area of the drilling operation,
an insert 202 is positioned within guide assembly 18 that is formed
of a metallic material that increases accuracy of the cuts as well
as durability. In one arrangement, as is shown, insert 202 has a
flat metallic face that is positioned in flush parallel alignment
to the drilling face 20. In this way, the insert 202 provides the
areas immediately adjacent to the oval shaped pocket hole to be
formed of durable and accurate metal, whereas the other portions of
guide assembly 18 are formed of a plastic material or composite
material or another non-metallic material. In one arrangement, this
insert 202 is connected to or formed as one with the drill guides
22. In one arrangement, the plastic material or composite material
or another non-metallic material of guide assembly 18 is formed
around the insert in a molding process or the like to provide
strength, rigidity, permanence and accuracy.
[0116] In the arrangement shown, drill guides 22 include an exit
hole 66 in their rear side, or a side opposite the drilling face
20. Exit holes 66 in drill guides 22 are formed of any suitable
size, shape and design and facilitate the removal of drilled
material such as wood chips, dust and debris. In the arrangement
shown, exit holes 66 are generally circular in shape when viewed
from the rear wall 58 of guide assembly 18. However any other shape
is hereby contemplated for use.
[0117] In the arrangement shown, an extended stop surface 112 is
positioned around the upper end of drill guides 22. Stop surfaces
112 are formed of any suitable size, shape and design and are
configured to provide a flat and flush surface to stop the forward
progression of drill bit 30. In the arrangement shown, when viewed
from above, stop surfaces 112 are generally cylindrical features
that rise slightly above the upper end 106 of guide assembly 18 in
the area immediately around each drill guide 22. Stop surfaces 112
are configured to engage a stop collar 114 connected to the drill
bit 30.
[0118] In the arrangement shown, the rear wall 58 of guide assembly
18 includes at least one opening 60 that is sized and shaped to
receive set pin 56 when guide assembly 18 is positioned at a set,
predetermined position, within upright portion 16 of base 12.
Alternatively, guide assembly 18 can be set to any other position
by moving the guide assembly 18 to the desired positon within
upright portion 16 of base 12 and tightening set pin 56 against
rear wall 58 thereby holding guide assembly 22 at the desired
position.
[0119] Also as is visible in the figures, the guide assembly 18 has
a partially skeletonized drilling face 20 and rear wall 58. This
skeletonized configuration allows the elimination of unnecessary
material while not reducing strength or rigidity or durability.
This skeletonized arrangement minimizes weight of the guide
assembly 18 and makes the guide assembly 18 easier to use. Also,
while portions of the drilling face 20 and rear wall 58 of guide
assembly 18 are skeletonized, enough material is left to form a
substantial plane at drilling face 20 to engage workpiece 26 and
rear wall 58 to engage opening 54 of upright portion 16 such that
the skeletonized configuration does not inhibit operation of the
guide assembly 18.
[0120] Drill Bit:
[0121] In the arrangement shown, system 10 includes the use of one
or more drill bits 30. Drill bit 30 is formed of any suitable size,
shape and design and is configured to be inserted within a drill
guide 22 having an inner diameter of corresponding size to the
outer diameter of the drill bit 30. The drill bit 30 is configured
to extend through drill guide 22 and into workpiece 26 thereby
forming a pocket hole.
[0122] In the arrangement shown, drill bit 30 includes an
adjustable stop collar 114 on a main body 116 that extends a length
from a cutting end 118 to an attachment end 120. In one
arrangement, main body 116 has an exterior diameter that
corresponds to the internal diameter of drill guide 22 and includes
a helical feature on and/or in its exterior surface that
facilitates the removal of material from workpiece 26. In one
arrangement the cutting end 118 includes a stepped feature that
facilitates the formation of stepped pocket holes. However any
other size, shape and design of a drill bit 30 is hereby
contemplated for use.
[0123] Grip Layer--On Guide Assembly:
[0124] In one arrangement, the main body of guide assembly 18 is
formed of a hard or rigid plastic or composite material and insert
202 is formed of a metallic material. This combination of using a
hard or rigid plastic or composite material for the main body of
guide assembly 18 and using a metallic material for insert 202
provides a strong, durable and long lasting tool that can handle
daily use and abuse without significant wear or damage. One
drawback, however, of using a hard or rigid plastic or composite
material for the main body of guide assembly 18 and using a
metallic material for insert 202 is that these materials tend to
have a low coefficient of friction. Or, said another way, when the
drilling face 20 of guide assembly 18 is placed on a workpiece 26
the low coefficient of friction of both the drilling face 20 of
guide assembly 18 and the workpiece 26 tends to be a relatively
slippery arrangement. As such, when guide assembly 18 having a main
body formed of a hard or rigid plastic or composite material and an
insert 202 formed of a metallic material is placed on workpiece 26,
there is a low coefficient of friction between the two components.
This means that the guide assembly 18 easily slides on and over
workpiece 26. This means that a substantial amount of clamping
pressure using clamp 204 is required to keep the relatively
slippery guide assembly 18 in place on the relatively slippery
workpiece 26 once the guide assembly 18 is placed in its desired
position on workpiece 26.
[0125] It is undesirable to have the guide assembly 18 move
relative to workpiece 26 once set in place on workpiece 26.
Movement of guide assembly 18 during a drilling operation can cause
an inaccurate pocket hole to be drilled. Also, movement of guide
assembly 18 during a drilling operation can cause injury to a user
if it causes the jig system 10, workpiece 26 and/or drill bit 30 or
attached drill to move.
[0126] Another drawback to having a low coefficient of friction
between guide assembly 18 and workpiece 26 is that substantial
clamping pressure is required to overcome the low coefficient of
friction between the guide assembly 18 and he workpiece 26 to clamp
the guide assembly 18 in place. This high level of clamping
pressure is undesirable for many reasons. Using excessive clamping
pressure can cause damage on the surface of the workpiece 26 as
pressing the clamp 204 and guide assembly 18 into workpiece 26 can
cause impressions, marks, mars and other signs of excessive
pressure. This is extremely undesirable especially for decorative
pieces, furniture and other display items. Using excessive clamping
pressure is also undesirable as it can lead to user fatigue over
time and can limit the number of operations a user can perform in a
day. Using excessive clamping pressure can lead to repetitive use
injuries for professional woodworkers such as cabinet makers,
furniture makers, craftsmen and the like. Using excessive clamping
pressure is also undesirable as it makes it more difficult to use
the guide assembly 18 as the user must ensure that the guide
assembly 18 is properly aligned with workpiece 26 during claiming
and applying the substantial clamping force. Using excessive
clamping pressure is also undesirable as it can damage the guide
assembly 18 over time. Using excessive clamping pressure is also
undesirable as may require specialized tools, such as metallic
project clamps, screw-tight clamps, a vise and the like tools that
can exert a substantial amount of pressure.
[0127] In one arrangement to provide both desired grip as well as
desired structural rigidity, guide assembly 18 includes a grip
layer 206. That is, the main body of guide assembly 18 is formed of
a generally rigid plastic material or composite material that
provides the needed structural rigidity to guide assembly 18. Due
to the material properties of this rigid and strong plastic or
composite material it tends to be relatively slick and has a low
coefficient of friction. As such, if this material itself were in
direct engagement with workpiece 26, the guide assembly 18 would
have a tendency to slip along the workpiece 26, or said another way
there would be a low coefficient of friction between the guide
assembly 18 and the workpiece 26.
[0128] To provide increased grip upon workpiece 26, the drilling
face 20 includes a layer (grip layer 206) formed of a more flexible
and/or more compressible material than the plastic or composite
material that forms the main body of guide assembly 18 and the
metallic material that forms the insert 202 of guide assembly 18.
Grip layer 206 is formed of any material that that has a higher
coefficient of friction than the main body of guide assembly 18 and
the metallic material that forms the insert 202, and therefore the
grip layer 206 provides enhanced grip on workpiece 26. The enhanced
grip of the grip layer 206 of guide assembly 18 allows the guide
assembly to better stay in place during a cutting operation thereby
allowing for a cleaner, more accurate and safer drilling
operation.
[0129] The high coefficient of friction of the material of grip
layer 206 also helps to hold the workpiece 26 in place and prevent
workpiece 26 and guide assembly 18 from moving during a drilling
operation thereby allowing for a cleaner, more accurate and safer
use.
[0130] In one arrangement, the grip layer 206 and main body of
guide assembly 18 are formed of a single piece construction, such
as molding the two components together such that they are
essentially inseparable. This monolithic formation may be made
through various manufacturing processes such as dual durometer
molding or dual material molding, or any other operation where two
different materials are molded together to form a single monolithic
and unitary member. Alternatively, the grip layer 206 and the main
body of guide assembly 18 may be formed independently of one
another and are then connected together by any manner, method or
means such as by using two sided tape, adhesive, gluing, cementing,
screwing, bolting, welding, using fitting features, using snap
fitting features, heat-activating, bonding, or the like, or by
connecting by any other manner, method or means. In another
arrangement, a first component is formed (either the grip layer 206
or the main body of guide assembly 18) through any process such as
extrusion, molding, casting, machining, forming or the like and the
second component (the other of the grip layer 206 or the main body
of guide assembly 18) is added to the formed first component in a
secondary manufacturing process such as molding, extrusion, spray
deposition or the like processes identified herein or any other
manufacturing process.
[0131] As one example, in one arrangement the main body of guide
assembly 18 is molded around the insert 202 and then the grip layer
206 is sprayed onto the main body of guide assembly 18.
[0132] As another example, in one arrangement the main body of
guide assembly 18 is molded around the insert 202 and then the grip
layer 206 is adhered onto the main body of guide assembly 18.
[0133] As another example, in one arrangement the main body of
guide assembly 18 is molded around the insert 202 and then the grip
layer 206 is molded onto the main body of guide assembly 18.
[0134] In one arrangement, grip layer 206 does not cover the
surface of insert 202. In this arrangement, the drilling face 20 of
insert 202 is flush or approximately flush with the grip layer 206
that covers the surfaces of the main body of drilling guide 18 that
form the drilling face 20.
[0135] In another arrangement, the grip layer 206 covers the
drilling face 20 of insert 202 as well as the surfaces of the main
body of drilling guide 18 that form the drilling face 20, either
partially or wholly. In one arrangement, the grip layer 206 covers
the entire drilling face 20 of the main body of drilling guide 18
that form the drilling face 20.
[0136] Said another way, grip layer 206 may cover all of the
drilling face 20 of the guide assembly 18, including the entire
plane of the forward surface of the main body of guide assembly 18
as well as the entire plane of the forward surface of insert 202,
whether skeletonized or not. The grip layer 206 may cover only some
or a portion of the drilling face 20 of the guide assembly 18,
including the forward surface of the main body of guide assembly 18
as well as the forward surface of insert 202. The grip layer 206
may cover only some or all of the drilling face 20 of the guide
assembly 18 but not any of the forward surface of insert 202. In
this arrangement, the forward surface of the insert 202 is flush
with the forward surface of the grip layer 206 on the main body of
guide assembly 18. This arrangement allows for optimum accuracy of
cutting the pocket hole as the hard metallic insert 202 engages the
surface of the workpiece 26 adjacent where the pocket hole is
drilled while the softer but higher coefficient of friction grip
material of grip layer 206 engages other portions of the workpiece
26, not precisely adjacent where the pocket hole is drilled.
[0137] In one arrangement, the grip layer 206 only covers portions
of the drilling face of the main body of drilling guide 18 that
form the drilling face 20. In this arrangement, the grip layer 206
may be formed of a plurality of strips or pieces or parts (which
may be formed of any size, shape and design, such as square,
rectangular, square or the like or any other shape) of the grip
layer material that extend across all or a part of the drilling
face 20 of the guide assembly 18. These strips may be flush with
the generally planar drilling face 20, or they may protrude
slightly from other portions of the planar drilling face 20 such
that when pressure is applied between the drilling guide 18 and the
workpiece 26 these protruding strips or pieces of grip material 206
are compressed flush with the drilling face 20. In this
arrangement, the grip layer 206 may be formed of isolated portions
of the grip layer material that are positioned on parts of the
drilling face 20 of the guide assembly 18, such as a circular,
square, rectangular or any other shaped member positioned in each
corner of the drilling face 20 of guide assembly 18. These isolated
portions of the grip layer 206 material may be flush with the
generally planar drilling face 20, or they may protrude slightly
from the planar drilling face 20. Any other arrangement of grip
layer 206 is hereby contemplated for use.
[0138] As an example of the grip layer 206 being placed in portions
on the drilling face 20 of guide assembly 18, with reference to
FIG. 4, a plurality of portions of grip layer 206A are shown on the
drilling face 20. In this example, the portions of grip layer 206A
appear as independent members, or feet, spaced across the drilling
face 20. In this arrangement, a portion of grip layer 206A is
positioned in each corner of the drilling face 20, approximately at
the center of the upper end, lower end and sides of the drilling
face, as well as across the central portion of the drilling face
20. In the arrangement shown, these portions of grip layer 206A are
shown as circular members when viewed from the forward side of
drilling face 20, however any other size, shape or design is hereby
contemplated for use. In addition, these portions of grip layer
206A may be flush with the forward plane of drilling face 20, or
alternatively, the portions of grip layer 206A protrude slightly
forward from the forward plane of drilling face 20 such that when
guide assembly 18 is clamped against a workpiece 26, the portions
of grip layer 206A compress to be flush with the plane of drilling
face 20.
[0139] These portions of grip layer 206A may be connected to guide
assembly 18 by any manner, method or means such as by using two
sided tape, adhesive, gluing, cementing, screwing, bolting,
welding, using fitting features, using snap fitting features,
heat-activating, bonding, or the like, or by connecting by any
other manner, method or means. In one arrangement, these portions
of grip layer 206A fit within openings in the drilling face 20 of
the guide assembly 18 and are friction-fitted therein, glued
therein, welded therein, adhered therein, screwed therein, molded
therein, formed therein, molded therein, or attached by any other
manner, method or means.
[0140] Durometer or Shore Durometer is one of several measures of
the hardness of a material. Higher numbers indicate harder
materials whereas lower numbers indicate softer materials. Hardness
may be defined as a material's resistance to indentation. Durometer
is typically used as a measure of hardness in plastics, composites,
polymers, elastomers, and rubbers, although it is applicable to
most if not all other materials as well. While the durometer of a
material does not necessarily or always define or correlate to the
coefficient of friction of a material (e.g. how much grip or stick
a material has when placed on another material) there is often a
high correlation with a material's durometer and its coefficient of
friction. That is, it is often the case that higher durometer
materials, which are harder, tend to have a low coefficient of
friction, meaning they are slicker, whereas in contrast lower
durometer materials, which are softer, tend to have a high
coefficient of friction, meaning they are sticker or provide more
grip when in contact with another material.
[0141] In one example, the material of main body of guide assembly
18 and insert 202 has a higher durometer and a lower coefficient of
friction compared to the grip layer 206 which has a lower durometer
and a higher coefficient of friction. As the main body of guide
assembly 18 is substantially thicker than the relatively thin grip
layer 206, the main body of guide assembly 18 provides structural
rigidity to guide assembly 18 while the grip layer 206 provides
increased grip. That is, the grip layer 206 is relatively soft in
comparison and has a high coefficient of friction that engages the
workpiece 26 and in this way, this combination harnesses the
benefits of both of these materials in a single piece. In one
arrangement, the thickness of the grip layer 206 is up to one
percent the thickness of the guide assembly 18, or is less than one
percent the thickness of the guide assembly 18, or is between zero
percent and one percent the thickness of the guide assembly 18. In
one arrangement, the thickness of the grip layer 206 is up to five
percent the thickness of the guide assembly 18, or is less than
five percent the thickness of the guide assembly 18, or is between
zero percent and five percent the thickness of the guide assembly
18. In one arrangement, the thickness of the grip layer 206 is up
to ten percent the thickness of the guide assembly 18, or is less
than ten percent the thickness of the guide assembly 18, or is
between zero percent and ten percent the thickness of the guide
assembly 18. In one arrangement, the thickness of the grip layer
206 is up to fifteen percent the thickness of the guide assembly
18, or is less than fifteen percent the thickness of the guide
assembly 18, or is between zero percent and fifteen percent the
thickness of the guide assembly 18. In one arrangement, the
thickness of the grip layer 206 is up to twenty percent the
thickness of the guide assembly 18, or is less than twenty percent
the thickness of the guide assembly 18, or is between zero percent
and twenty percent the thickness of the guide assembly 18. Any
other thickness or range of thicknesses for grip layer 206 is
hereby contemplated for use.
[0142] One benefit to using a material that has a high coefficient
of friction for grip layer 206 is that the grip layer can be
smooth, or said another way the drilling face 20 can be smooth,
while providing the necessary grip on workpiece 26. That is, in
contrast using a roughened or textured surface on drilling face 20,
such as sand paper, serrations or grooves in the drilling face 20,
a pattern of points, cross-hatching, a rough surface, a machined
roughness, machining marks or any other roughened surface, which
can cause marring or scarring on the workpiece 26, use of a smooth
grip layer 206 does not cause marring or scarring. In fact, using a
compressible material for grip layer 206 has a tendency to cause
less scarring, marking or marring as the compressible material of
grip layer 206 has a tendency to accommodate any debris or partials
that get in-between the workpiece 26 and the drilling face 20 of
guide assembly 18 due to its compressible nature. In contrast, when
using a hard-surfaced drilling face 20 of guide assembly 18 these
particles or debris would be pressed into the surface of the
workpiece 26 thereby causing undesirable aesthetical displeasing
features. As such, using a compressible material that has a high
coefficient of friction is more forgiving, has less potential to
mark the workpiece 26, and provides superior performance over a
roughened surface for providing grip on drilling face 20.
[0143] Grip layer 206 may be formed of any material that has a
higher coefficient of friction than the rigid material that the
base 12, guide assembly 18, insert 202 or other components of the
system 10 are formed of. As examples, grip layer 206 may be formed
of a rubber material, a natural rubber material, a synthetic rubber
material, a silicone material, an isoprene rubber material,
ethylene propylene diene (EPDM) material, a nitrile rubber (NBR)
material, a styrene butadiene rubber (SBR) material, a silicone
rubber material, a butyl rubber material, a isobutylene isoprene
rubber material, a polybutadiene rubber material, a foam rubber
material, any compressible or high coefficient of friction plastic
material, or any other material that is more-compressible than
and/or has a higher coefficient of friction than the rigid
materials of the base 12, guide assembly 18, insert 202 or other
components of the system 10 that the grip layer 206 is attached
to.
[0144] Grip Layer--On Base:
[0145] While grip layer 206 has been described herein as being
placed on drilling face 20 of guide assembly 18, it is hereby
contemplated that grip layer 206 may be placed on any place or
portion of jig system 10 that comes into contact with or could come
into contact with workpiece 26.
[0146] In one arrangement, the upper surface 38 of lower portion 14
of base 12 also includes a grip layer 206 thereon. Grip layer 206
may be placed on the upper surface 38 of lower portion 14 of base
12 for the same reasons described herein with respect to placing
grip layer 206 on the drilling face 20 of guide assembly 18. Grip
layer 206 on the upper surface 38 of lower portion 14 of base 12
may be formed of the same material as grip layer 206 on drilling
face 20 of guide assembly 18 as is described herein, or
alternatively a different material may be used. Grip layer 206 on
the upper surface 38 of lower portion 14 of base 12 may be used for
the same reasons described herein with respect to placing grip
layer 206 on the drilling face 20 of guide assembly 18. Grip layer
206 on the upper surface 38 of lower portion 14 of base 12 may be
attached and/or affixed and/or formed in the same or a different
manner described herein with respect to grip layer 206 on the
drilling face 20 of guide assembly 18.
[0147] That is, placing grip layer 206 on the upper surface 38 of
lower portion 14 of base 12 is configured to engage the end of
workpiece 26 when workpiece 26 is placed within jig system 10. As
such, the engagement of the end of workpiece 26 with the grip layer
206 on the upper surface 38 of lower portion 14 of base 12 is
configured to hold workpiece 26 in place in jig system 10 and
prevent workpiece 26 from unintentionally sliding within jig system
10 and moving during clamping.
[0148] In the arrangement shown, as one example, grip layer 206 is
placed on the upper surface 38 of lower portion 14 of base 12 is
placed on the area of the upper surface 38 of lower portion 14 of
base 12 adjacent the drilling face 20 of guide assembly 18 and
adjacent the area where plunger pad 102 engages workpiece 26. This
area is shown as area "A" in FIG. 2. Said another way, grip layer
206 may cover all or a portion of the area of upper surface 38 of
lower portion 14 of base 12 between the drilling face 20 of guide
assembly 18 and the plunger pad 102 of clamping assembly 24. Grip
layer 206 may cover all or a portion of the surface area of the
upper surface 38 of lower portion 14 of base 12 between drilling
face 20 of clamp assembly 18 and plunger pad 102.
[0149] Grip Layer--On Forward Wall of Upright Portion of Base:
[0150] In one arrangement, the forward wall 50 of upright portion
16 of base 12 also includes a grip layer 206 thereon. Placement of
grip layer 206 on the forward wall 50 of upright portion 16 of base
12 is particularly important and helpful in arrangements of jig
system 10 wherein the forward wall 50 of upright portion 16 of base
12 is in flush planar alignment with the drilling face 20 of guide
assembly 18. Grip layer 206 may be placed on the forward wall 50 of
upright portion 16 of base 12 for the same reasons described herein
with respect to placing grip layer 206 on the drilling face 20 of
guide assembly 18. Grip layer 206 on the forward wall 50 of upright
portion 16 of base 12 may be formed of the same material as grip
layer 206 on drilling face 20 of guide assembly 18 as is described
herein, or alternatively a different material may be used. Grip
layer 206 on the forward wall 50 of upright portion 16 of base 12
may be used for the same reasons described herein with respect to
placing grip layer 206 on the drilling face 20 of guide assembly
18. Grip layer 206 on the forward wall 50 of upright portion 16 of
base 12 may be attached and/or affixed and/or formed in the same or
a different manner described herein with respect to grip layer 206
on the drilling face 20 of guide assembly 18.
[0151] Grip Layer--On Plunger Pad:
[0152] In one arrangement, the surface of plunger pad 102 that
engages workpiece 26 also includes a grip layer 206 thereon. Grip
layer 206 may be placed on the surface of plunger pad 102 that
engages workpiece 26 for the same reasons described herein with
respect to placing grip layer 206 on the drilling face 20 of guide
assembly 18. Grip layer 206 on the surface of plunger pad 102 that
engages workpiece 26 may be formed of the same material as grip
layer 206 on drilling face 20 of guide assembly 18 as is described
herein, or alternatively a different material may be used. Grip
layer 206 on the surface of plunger pad 102 that engages workpiece
26 may be used for the same reasons described herein with respect
to placing grip layer 206 on the drilling face 20 of guide assembly
18. Grip layer 206 on the surface of plunger pad 102 that engages
workpiece 26 may be attached and/or affixed and/or formed in the
same or a different manner described herein with respect to grip
layer 206 on the drilling face 20 of guide assembly 18.
[0153] Grip Layer--On Any Other Surface That Engages Workpiece:
[0154] It is hereby contemplated that grip layer 206 may be placed
on any other surface that engages workpiece 26. Grip layer 206 may
be placed on these surfaces for the same reasons described herein
with respect to placing grip layer 206 on the drilling face 20 of
guide assembly 18. Grip layer 206 placed on these surfaces may be
formed of the same material as grip layer 206 on drilling face 20
of guide assembly 18 as is described herein, or alternatively a
different material may be used. Grip layer 206 on these surfaces
may be used for the same reasons described herein with respect to
placing grip layer 206 on the drilling face 20 of guide assembly
18. Grip layer 206 on these surfaces may be attached and/or affixed
and/or formed in the same or a different manner described herein
with respect to grip layer 206 on the drilling face 20 of guide
assembly 18.
[0155] It is also important to note that other configurations of
pocket hole jig system 10 are hereby contemplated for use and the
same teachings provided herein apply. That is, it is contemplated
that various configurations of jig system 10 may look completely
different than the jig presented in FIGS. 1-4 while the teachings
presented herein apply equally. Also, the orientation of parts in
different manners is hereby contemplated while the teaching
presented herein apply equally.
[0156] That is, as one example, it is contemplated that the guide
assembly 18 may be attached to the clamping assembly 24. In this
arrangement, the workpiece 26 is forced into engagement with the
forward wall 50 of upright portion 16 of base 12 on one side, and
the drilling face 20 of guide assembly 18 (which is the movable
part attached to clamping assembly 24) on the other side. In one
arrangement, only the forward wall 50 of upright portion 16 of base
12 includes grip layer 206 thereon. In another arrangement, both of
the forward wall 50 of upright portion 16 of base 12 on one side,
and the drilling face 20 of guide assembly 18 on the other side
include grip layer 206 thereon.
[0157] As such, it is contemplated that workpiece 26 may be clamped
between opposing stop surfaces, one stop surface which is immovable
or stationary in nature, and the other which is movable in nature
by way of clamping assembly 24. In this way, workpiece 26 may be
clamped between two opposing stop surfaces. In one arrangement,
only one of these opposing stop surfaces include grip layer 206,
which may be either the movable stop surface or the immovable stop
surface. In another arrangement, both of these opposing stop
surfaces include grip layer 206 thereon that help to hold workpiece
26 in place due to the high coefficient of friction of the grip
layer 206. This may include only the forward wall 50 of upright
portion 16 having grip layer 206 thereon. This may include only the
drilling face 20 of guide assembly 18 having grip layer 206
thereon. This may include only the forward face of plunger pad 102
of clamping assembly 24 having grip layer 206 thereon. This may
include any combination of these components, forward wall 50 of
upright portion 16, drilling face 20 of guide assembly 18 and/or
forward face of plunger pad 102 of clamping assembly 24, having
grip layer 206 thereon.
[0158] In Operation--Use in a Jig:
[0159] In operation, to form pocket holes using jig 10, guide
assembly 18 is placed in the opening 54 of upright portion 16 of
base 12 (or alternatively into a portable base 208 as is further
described herein). The guide assembly 18 is moved to the
appropriate height and the set pin 56 is engaged into the rear wall
58 of the guide assembly 18 thereby locking the guide assembly 18
in place. Next, a workpiece 26 is placed on the base 12. The
interior face of the workpiece 26 is placed against the drilling
face 20 of the guide assembly 18 and the end of the workpiece is
placed on the upper surface 38 of the lower portion 14 of base 12
adjacent to the drilling face 20 of guide assembly 18. Once
workpiece 26 is in this position on jig 10 the handle assembly 72
is moved from a non-clamping position to a clamping position
thereby forcing the plunger pad 102 against the workpiece 26
thereby clamping the workpiece 26 in place.
[0160] In this position, the grip layer 206 of the drilling face 20
guide assembly 18 and/or the grip layer 206 on the upper surface 38
of the lower portion 14 of base 12 and/or the grip layer 206 on the
forward wall 50 of the upright portion 16 of base 12 and/or the
grip layer 206 on the face of the plunger pad 102 directly engages
the workpiece 26. The higher coefficient of friction of the
material of grip layer 206 provides increased grip on workpiece 26
thereby providing a better hold between guide assembly 18 and
workpiece 26 thereby preventing movement of workpiece 26 during use
and requiring less clamping pressure to hold the workpiece 26 in
place. When the clamping assembly 24 is tightened the grip layer
206 of the drilling face 20 guide assembly 18 and/or the grip layer
206 on the upper surface 38 of the lower portion 14 of base 12
and/or the grip layer 206 on the forward wall 50 of the upright
portion 16 of base 12 and/or the grip layer 206 on the face of the
plunger pad 102 compresses while holding the workpiece 26 in place.
This slight compression has a tendency to be accommodating to the
workpiece 26 and prevents marking or marring the surfaces of
workpiece 26 as forces are dispersed instead of focused at
particular points. In this way, a firm, strong and accommodating
hold between jig system 10 and workpiece 26 is generated by the jig
system 10 presented herein.
[0161] In one arrangement, wherein the grip layer 206 protrudes
outward slightly from the plane of the drilling face 20 as the
workpiece 26 is clamped against the drilling face 20 the protruding
portions of grip layer 206 compress so as to be flush with the
plane of the drilling face 20.
[0162] In Operation--Use of Drilling Guide:
[0163] In an alternative arrangement, instead of using the drilling
guide 18 in jig 10 the guide assembly 18 may be used alone on
workpiece 26 without jig 10. In this arrangement, the drilling face
20 of guide assembly 18 is placed on a surface of workpiece 26.
When in the desired position, the guide assembly 18 is clamped into
place using clamp 204.
[0164] In this position, the grip layer 206 of the guide assembly
18 directly engages the workpiece 26. The higher coefficient of
friction of the material of grip layer 206 provides increased grip
on workpiece 26 thereby providing a better hold between guide
assembly 18 and workpiece 26 thereby preventing movement of
workpiece 26 during use and requiring less clamping pressure to
hold the workpiece 26 in place.
[0165] In one arrangement, wherein the grip layer 206 protrudes
outward slightly from the plane of the drilling face 20 as the
workpiece 26 is clamped against the drilling face 20 the protruding
portions of grip layer 206 compress such to be flush with the plane
of the drilling face 20.
[0166] Portable Base:
[0167] While guide assembly 18 may be use in jig 10 or in a
standalone manner, guide assembly 18 may also be used in portable
base 208. One arrangement of portable base 208 is shown in FIGS.
14-21. Portable base 208 is formed of any suitable size, shape and
design and is configured to hold guide assembly 18 in an adjustable
manner and facilitate setting the position of guide assembly 18 on
workpiece 26 in an efficient and repeatable manner.
[0168] In the arrangement shown, as one example, portable base 208
is essentially upright portion 16 of jig 10 without the other
portions of the larger assembly of jig 10. That is, in the
arrangement shown, as one example, portable base 208 includes rear
wall 48, forward wall 50, upper wall 52, opening 54 and exit holes
64 as is described herein. The lower end of portable base 208 also
includes a lip 210 that extends forward past the plane of forward
wall 50 a distance and forms a plane aligned in approximate
perpendicular alignment to the plane formed by drilling face 20 of
guide assembly 18 and/or forward wall 50 of portable base 208. Lip
210 essentially forms a small portion of lower portion 14 of base
12 and serves as a stop surface for portable base 208. That is, lip
210 extends in approximate perpendicular alignment to the plane
established by forward wall 50. In use, the forward wall 50 is
placed on the surface of workpiece 26 that is to be drilled and the
lip 210 is engaged with the edge of workpiece 26. In this way, lip
210 indexes or sets the position of drill guide 18 and portable
base 208 with respect to an edge or end of workpiece 26.
[0169] Like upright portion 16 of jig system 10, the position of
guide assembly 18 within portable base 208 is adjustable. That is
the portable base 208 includes a set pin 56 that sets the depth of
the drill guide 18 with respect to portable base 208. Once the
position of the drill guide 18 is set within portable base 208 and
the portable base 208 is aligned with the edge or end of workpiece
26 the portable base 208 and drill guide 18 are clamped in place
using clamp 204.
[0170] Grip layer 206 may be placed on the drilling face 20 and/or
insert 202 of guide assembly 18. Grip layer 206 may also be placed
on the forward wall 50 and/or the upper surface of lip 210 as these
surfaces engage workpiece 26.
[0171] As is described herein, the grip layer 206 on drilling guide
18 provides increased grip upon workpiece 26, whether drilling
guide 18 is used in jig 10, portable base 208 or in a standalone
capacity.
[0172] Grip Layer on Forward Wall: In one arrangement, grip layer
206 is only placed on the drilling face 20 of guide assembly 18. In
this arrangement, the drilling face 20 of guide assembly extends
slightly past the forward wall 50 of drilling jig 10 and/or
portable base 208 when guide assembly 18 is in place therein. In
this way, this slight protrusion of drilling face 20 past forward
wall 50 ensures direct engagement of drilling face 20/grip layer
206 with workpiece 26.
[0173] In an alternative arrangement, the drilling face 20 of guide
assembly 18 is in approximate planar alignment with the forward
face of forward wall 50 such that the two planar faces engage the
surface of a workpiece 26 at the same time. In one arrangement, the
forward face of forward wall 50 includes a grip layer 206 thereon
in the same or a similar manner described herein with respect to
guide assembly 18. The presence of grip layer 206 on forward wall
50 increases the grip between jig 10 and/or portable base 208 in
the manner described herein with respect to guide assembly 18.
[0174] Alternative Arrangements:
[0175] The use of grip layer 206 is hereby contemplated for use on
any guide assembly 18 and/or jig or jig system.
[0176] As further examples, with reference to FIGS. 4-21,
Applicant's guide assembly used in association with its K3, K4 and
K5 products is shown used in association with grip layer 206. This
guide assembly 18 includes three drill guides 22 and a substantial
insert 202 that occupies a portion of drilling face 20 that is
metallic. This guide assembly 18 can be used with jig system 10,
with portable base 208 as well as in a standalone manner.
[0177] With reference to FIGS. 22-30, Applicants mini jig is shown
as guide assembly 18 and used in association with grip layer 206.
This guide assembly 18 has a single drill guide 22 that intersects
drilling face 20. While the guide assembly shown in FIGS. 22-30 is
configured differently than that shown in FIGS. 1-21, the teachings
apply equally. That is, grip layer 206 may be used on the drilling
face 20 of guide assembly 18.
[0178] With reference to FIGS. 31-38, Applicant's R3 product is
shown used in association with grip layer 206. This guide assembly
18 has a pair of drill guides 22 that intersect drilling face 20.
This guide assembly 18 also has an attachment member 212 that
facilitates connection of a clamp 204 to the guide assembly 18.
This guide assembly 18 also includes moveable or slidable alignment
members 214 that include a lip 216 that extend below the drilling
face 20 that are used to set the position of guide assembly 18 as
well as align the guide assembly 18 with an edge of a workpiece 26.
Again, while the guide assembly shown in FIGS. 31-38 is configured
differently than that shown in FIGS. 1-21, or FIGS. 22-30 the
teachings apply equally. That is, grip layer 206 may be used on the
drilling face 20 of guide assembly 18 as well as the forward faces
of attachment member 212 and the upper surfaces of lip 216, as well
as any other surface that may engage workpiece 26.
[0179] In this way the system 10 is used to form pocket holes and
all of the objectives of the disclosure are met.
[0180] Although specific embodiments have been illustrated and
described herein, it will be appreciated by those of ordinary skill
in the art that any arrangement which is calculated to achieve the
same purpose may be substituted for the specific embodiments shown.
This application is intended to cover any adaptations or variations
of the invention. It is intended that this invention be limited
only by the following claims, and the full scope of equivalents
thereof
* * * * *