Abstract:
A tool holder formed from two or more layers of material is provided. Cutouts or pockets may be formed in the tool holder corresponding with specific types and sizes of tools. An identification for each tool may be provided on the tool holder adjacent to each cutout. The identification remains visible to a reader when an associated tool is placed in each respective cutout.

Description:
RELATED APPLICATION 
   This application claims priority to U.S. Provisional Patent Application Ser. No. 60/623,924, filed Nov. 1, 2004 and entitled “TOOL HOLDER,” the contents of which are hereby incorporated in their entirety by reference. 

   TECHNICAL FIELD 
   The present invention is related to tool holders having cutouts or pockets shaped to receive a specific size and type of tool and more particularly to tool holders formed from two or more layers of material. 
   BACKGROUND OF THE INVENTION 
   Tool boxes and tool chests frequently hold a wide variety of tools and other devices. Tool boxes and tool chests may include one or more drawers for specific types of tools. Such tool boxes and tool chests may include molded plastic inserts sized to receive specific sizes and types of tools. The type and/or size of the tool contained within each drawer may be printed on the exterior of the drawer. Also, the type and/or size of each tool may be printed on the molded plastic insert contained within the drawer. 
   Many industries call for the use of unique tools which are not compatible with large volume commercially available tool boxes and tool drawers. These industries often place a high premium on keeping track of valuable tools and ensuring that all tools are fully accounted for at the end of a work process, work shift or work day. For example, during repair and assembly of a jet engine, checklists and associated procedures are required for accounting for all tools after completion of a repair and assembly. The same requirements often apply to repair of complex systems such as electrical power generating equipment, nuclear reactors, etc. Foreign object debris or foreign object damage (FOD) is a well known problem associated with operation of jet engines and similar types of equipment. 
   Positive control of expensive tools and associated tooling has become an important part of modern industry. The United States government and similar organizations typically have procedures and requirements for positive control of tools and tooling. 
   SUMMARY OF THE INVENTION 
   In accordance with teachings of the present invention, a tool holder and method of forming a tool holder are provided to overcome many of the shortcomings and disadvantages associated with prior tool holders. One aspect of the present invention includes providing a tool holder which may be fabricated at relatively low cost from two or more layers of material. Tool holders formed in accordance with teachings of the present invention may be used to substantially reduce or eliminate foreign object debris or foreign object damage (FOD) after repair and maintenance of complex equipment such as jet engines and large water pumps. Such tool holders may be used in a wide variety of industries from aircraft maintenance to nuclear reactor repair to complex surgical procedures to ensure that all tools and other objects have been accounted for after completion of an associated procedure. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A more complete and thorough understanding of the present embodiments and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings, in which like reference numbers indicate like features, and wherein: 
       FIG. 1  is a schematic drawing showing an isometric view of one example of a tool holder incorporating teachings of the present invention; 
       FIG. 2  is a schematic drawing showing an exploded, side view of a tool holder formed in accordance with teachings of the present invention; 
       FIG. 3  is a schematic drawing showing an isometric, exploded view with portions broken away of multiple layers of material forming an elongated blank in accordance with teachings of the present invention; 
       FIG. 4  is a schematic drawing in sections showing portions of a tool holder formed from the manufacturing blank of  FIG. 3 ; 
       FIG. 5  is a schematic drawing showing an isometric, exploded view with portions broken away of multiple layers of material forming an elongated, manufacturing blank in accordance with teachings of the present invention; and 
       FIG. 6  is a schematic drawing in section showing portions of a tool holder formed from the manufacturing blank of  FIG. 5 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Preferred embodiments of the invention and its advantages are best understood by reference to  FIGS. 1-6  wherein like numbers refer to same and like parts. 
   The term “tool holder” may be used in this application to describe any type of component or assembly formed in accordance with teachings of the present invention satisfactory for holding tools, tooling, devices or any other objects. 
   Tool holder  20  may be formed from multiple layers of material in accordance with teachings of the present invention. Tool holder  20  and associated layers of material may be formed in accordance with teachings of the present invention having various configurations including square, rectangular, triangular, circular, oval or any other satisfactory configuration. Multiple cutouts or pockets may be formed in tool holder  20  to receive respective tools or other devices. For example, cutouts  22 ,  24  and  26  as shown in  FIG. 1  may be formed in tool holder  20  to receive respective tools (not expressly shown) having corresponding dimensions and configurations. 
   For some applications tool holder  20  may have two components or subassemblies designated as  30  and  60 . First component or upper component  30  may be formed from two or more layers of material. Second component or lower component  60  may also be formed from two or more layers of material. First component or upper component  30  is also shown in  FIG. 4 . Second component or lower component  60  is also shown in  FIG. 6 . 
   Embodiments such as shown in  FIGS. 1-6  may include first component or upper component  30  having first layer  32  formed from relatively tough, clear material and second layer  34  formed from relatively lightweight foam. For some applications second layer  34  may have a thickness substantially greater than the thickness of layer  32 . 
   Embodiments such as shown in  FIGS. 1-6  may include second component or lower component  60  having layer  62  formed from relatively tough, clear material and layer  64  formed from relatively lightweight foam. For some applications layer  64  may have a thickness substantially greater than the thickness of layer  62 . Adhesive material  36   a ,  36   b  and  36   c  may be respectively disposed between and bonded with layers  32  and  34 , layers  34  and  62  and layers  62  and  64 . See  FIG. 2 . 
   For some tool holders, layers  32  and  62  may be formed from the same material. For other applications layers  32  and  62  may be formed from different materials. In a similar manner, layers  34  and  64  may be formed from the same material. For other applications layers  34  and  64  may be formed from different materials. For example, layers  32  and/or  62  may be formed from clear plastic film or sheets of polyester film and polycarbonate, polyethylene and polypropylene. Mylar® films from DuPont may be used for some applications. Layers  34  and  64  may be formed from closed cell cross-linked polyethylene foam. A wide variety of other materials may be satisfactorily used to form layers  32 ,  34 ,  62  and  64 . 
   First layer  32  preferably includes first surface  32   a  and second surface  32   b . A name corresponding with a tool that may be placed in each cutout  22 ,  24  and  26  is preferably imprinted on the reverse side or second surface  32   b  of layer  32 . The location of the name for each cutout  22 ,  24  and  26  may be placed on second surface  32   b  at a location proximate the desired location for forming the respective cutouts  22 ,  24  and  26 . Each name is preferably visible even when an appropriate tool is placed in respective cutout  22 ,  24  and  26 . For some applications the names may be imprinted on first surface  32   a . Adhesive material  36   a may be disposed between layers  32  and  34 . 
   Second layer  34  preferably includes first surface  34   a  and second surface  34   b . Adhesive material  36   b  may be disposed on second surface  34   b . Release liner  38  may be attached with adhesive material  36   b  opposite from second surface  34   b  prior to assembly of first component  30  with second component  60 . Layer  62  of second component  60  includes first surface  62   a  and second surface  62   b . In a similar manner, layer  64  includes first surface  64   a  and second surface  64   b . See  FIG. 2 . 
   Various procedures and techniques may be satisfactorily used to form tool holders from two or more layers of material in accordance with teachings of the present invention. For some applications relatively long, thin strip of clear plastic film  132  and relatively long strip of plastic foam  134  may be used to form multiple upper components  30 . See  FIG. 3 . In a similar manner relatively long, thin strip of clear plastic film  162  and relatively long strip of plastic foam  164  may be used to form multiple lower components  60 . See  FIG. 5 . 
   For embodiments such as those shown in  FIG. 3 , clear plastic film strip  132  may be formed with a width corresponding with the desired width for each top layer or first layer  32 . The length of strip  132  may be selected to correspond with the number of top layers  32  which will be formed therefrom. Also, respective tool names for each cutout which will later be formed in top layer  32  may be preprinted at appropriate locations corresponding with respective second surfaces  32   b . See  FIG. 3 . 
   Foam strip  134  may be formed with approximately the same width as clear plastic film strip  132 . The length of foam strip  134  may be approximately equal to the length of clear plastic film strip  132 . Various techniques such as heat sealing, sonic bonding and/or adhesive bonding may be satisfactorily used to attach plastic strip  132  with foam strip  134 . For example, adhesive material  36   a  may be used to attach layer  32  with layer  34 . 
   Adhesive material  36   b  may be disposed on one side of foam strip  134  which will correspond with second side  34   b  of respective second layers  34 . Release liner strip  138  may be attached with adhesive material  36   b . Plastic strip  132 , foam strip  134 , adhesive material  36   b  and release liner strip  138  may be bonded with each other to form elongated manufacturing blank  130 . See  FIG. 3 . Elongated manufacturing blank  130  may be cut at respective dotted lines  40  to form individual manufacturing blanks corresponding with each upper component  30 . For some applications clear plastic film strip  132 , foam strip  134  and release liner strip  138  may be taken from substantially continuous rolls for each type of material. 
   Cutouts  22 ,  24  and  26  may be formed in respective portions of clear plastic strip  132  and foam layer  134  prior to cutting individual manufacturing blanks corresponding with each upper component  30 . For other applications, individual manufacturing blanks with dimensions corresponding with upper component  30  may be cut from elongated manufacturing blank  130  prior to forming cutouts  22 ,  24  and  26 . 
   For some applications, cutouts  22 ,  24  and  26  may extend through clear plastic layer  32  and foam layer  34 . Depending upon the type of cutting procedure used, release liner  38  may remain intact (kiss cutting) or portions of release liner  38  may also be cut out during the same process. For some applications, cutouts  22 ,  24  and  26  may only extend partially through foam layer  34 . For such applications it may not be necessary to attach second component or lower component  60  with first component or upper component  30 . First components  30  may function satisfactorily as a tool holder depending upon the amount of material remaining at the bottom of each cutout. 
   For embodiments such as shown in  FIG. 5 , clear plastic film strip  162  may be formed with a width corresponding with the desired width for each layer  62 . The length of strip  162  may be selected to correspond with the number of layers  62  which will be formed therefrom. Foam strip  164  may be formed with approximately the same width as clear plastic film strip  162 . The length of foam strip  164  may be approximately equal to the length of clear plastic film strip  162 . Various techniques such as heat sealing, sonic bonding or adhesive bonding may be satisfactorily used to attach plastic strip  162  with foam strip  164  to form elongated manufacturing blank  160 . For example, adhesive material  36   c  may be used to attach layer  62  with layer  64 . Dotted lines  80  correspond with cuts which may be made in elongated manufacturing blank  60  to form corresponding second components  60 . 
   After upper component  30 , such as shown in  FIG. 4 , has been formed, release liner  38  may be removed from adhesive material  36   b . Second surface  34   b  and associated adhesive material  36   b  of first component  30  may then be placed on first surface  62   a  of second component  60  to complete assembly of tool holder  20 . 
   Alternative embodiments of the present invention may include attaching only layer  62  with second surface  34   b  of component  30 , attaching only layer  64  with second surface  34   b  or using first component  30  as a tool holder without attaching any other layers to second surface  34   b . For some applications, release liner  38  may be removed from second surface  34   b  and adhesive material  36   b  attached directly to the top of a work surface, the bottom of a tool drawer or any other desired location for storage of the tools which may be placed in cutouts  22 ,  24  and  26 . 
   Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alternations can be made herein without departing from the spirit and scope of the invention as defined by the following claims.