Abstract:
Improvements in a LED puck light drill jig is disclosed. The adjustable LED puck light drill jig is adjustable to be consistent and repeatable. The jig has a location for drilling a recessed hole for a puck light at a fixed depth to allow the puck light to be recessed in a wall or shelf. An orthogonal drill guide is pre-aligned with the hole for the puck light. The drill guide is further aligned with the centerline of the wall or shelf to provide a maximum amount of material on both sides of the wall or shelf. The drill guide has a relief for removed material to be expelled rather than transporting the material to the extreme end of the drill guide.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of applicant&#39;s co-pending application Ser. No. 62/061,272 filed Oct. 8, 2014 the entire contents of which is hereby expressly incorporated by reference herein. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not Applicable 
       THE NAMES OF THE PARTIES TO A JOINT RESEARCH AGREEMENT 
       [0003]    Not Applicable 
       INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
       [0004]    Not Applicable 
       BACKGROUND OF THE INVENTION 
       [0005]    1. Field of the invention 
         [0006]    This invention relates to improvements in a drill jig for installing puck lights. More particularly, the present drill jig provides a complete solution for drilling a hole for a puck light and drilling a parallel hole in the shelf or wall for routing wiring to the puck light hole. 
         [0007]    2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98. 
         [0008]    Installing lighting under cabinets can take a variety of different types. Puck lights are one typical type of lighting. Installing the lighting requires that the puck light is placed on the surface of the wall or shelf where the wiring is exposed on the outer surface of the wall or shelf. Another method is to place the puck light of one side of the shelf or wall and place a hole through the wall or shelf where the wiring is placed on the back side of the wall or shelf. In both of these cases exposed wiring is on an outer surface of the cabinet. Because each installation is unique for the location of the puck light on the wall or shelf the only way to conceal wiring in a shelf or cabinet requires a hole to be drilled parallel to the thickness of the shelf or wall. 
         [0009]    There have been some drilling jigs or guides for placing one or more holes through doors or shelves, but these do not provide adjustments for placing the holes for puck lighting at nearly any location on a wall or shelf. A number of patents and or publications have been made to address these issues. Exemplary examples of patents and or publication that try to address this /these problem(s) are identified and discussed below. 
         [0010]    U.S. Pat. No. 2,798,520 issued on Jul. 9, 1957 to J. M. Maskulka et al., discloses a Drill Guide. This drill guide has a plurality of cylindrical passageways for drilling two parallel holes. The parallel holes allow for insertion of dowels for securing corners of a picture frame. While this patent provides a drill guide, there are no adjustments on the drill guide for the dimensions between the drilled holes and further does not allow for drilling the two holes orthogonal to each other. 
         [0011]    U.S. Pat. No. 6,910,837 issued on Jun. 28, 2005 to David J. Trettin et al discloses a Lockset Drilling Guide. The drilling guide provides for drilling two orthogonal holes for insertion of a door knob and latch mechanism. There are no adjustments for the dimensions between the two holes, and the two holes are used with circular saws to make the holes. Because door locksets have the same geometry the only adjustment is how for the holes are made from one end of the door. The hole for the door knobs are through holes and do not include a method to drill a finite depth for insertion of a puck light into a recessed hole. 
         [0012]    U.S. Pat. No. 7,073,990 issued on Jul. 11, 2006 to Ursula Poeckl discloses a Dowel Gauge. The dowel gauge has a single drill guide hole with indicia for moving the single drill guide for drilling additional holes at the same distance apart. The dowel gauge in re-positioned to drill opposing holes for the dowel holes. While this provides a drill guide it does not include a guide for drilling a recessed hole for insertion of a light puck. 
         [0013]    What is needed is a drill jig that allows an installer to drill a recessed hole and an orthogonal hole for wiring. The proposed adjustable LED puck light drill jig provides the solution with an adjustable jig where puck light can be repeatedly placed at a desired location in a wall of shelf. 
       BRIEF SUMMARY OF THE INVENTION 
       [0014]    It is an object of the adjustable LED puck light drill jig to allow for drilling a hole for a LED puck light. The drilling of the hole for the puck light is made to a finite depth into the wall or shelf. The finite depth allows the puck light to be recessed into the wall or shelf without protruding into the other side of the wall or shelf and also reduces the amount of exposure of the puck light. A stop of a forstner or similar hole drilling bit is used to create a round hole with a flat smooth finished bottom surface where the LED puck light is inserted. 
         [0015]    It is an object of the adjustable LED puck light drill jig to drill a hole parallel to the surface of a wall or shelf. The drill guide is pre-aligned with the hole for the puck light. The drill guide is further aligned with the centerline of the wall or shelf to provide a maximum amount of material on both sides of the wall or shelf. An installer drills the hole through to the hole created for the puck light. Wiring can then be placed through this parallel hole to provide electricity to an installed puck light. 
         [0016]    It is another object of the adjustable LED puck light drill jig to be adjustable to distance from the back of the wall or shelf. Each installation can be located a different distance from a front or back side and can include multiple puck lights spaced along a shelf, wall or ceiling. Often the location is dictated by a customer or lighting requirements. The depth of the shelf or wall can also be a variable. The drill jig has adjustments so the dimensions between multiple pick lights is consistent and repeatable. 
         [0017]    It is still another object of the adjustable LED puck light drill jig to have a chip relief area to clear material that has been removed by the drill. Because the length of the drill guide can be long to ensure that the drill passes parallel to the sides of the shelf, wall or side of cabinet, material that is removed from the drill must be transported from the tip of the drill to a location outside of the drill guide. The drill guide has a relief for removed material to be expelled rather than transporting the material to the extreme end of the drill guide. 
         [0018]    Various objects, features, aspects, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the invention, along with the accompanying drawings in which like numerals represent like components. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         [0019]      FIG. 1  shows a bottom perspective view of an adjustable LED puck light drill jig. 
           [0020]      FIG. 2  shows a top perspective view of the adjustable LED puck light drill jig. 
           [0021]      FIG. 3  shows a top perspective view of the adjustable LED puck light drill jig in a cabinet wall or shelf. 
           [0022]      FIG. 4  shows a top perspective view of the adjustable LED puck light drill jig clamped on a shelf. 
           [0023]      FIG. 5A  shows a cutter for a puck light with a depth stop. 
           [0024]      FIG. 5B  shows the cutter for the cutter for a puck light with the depth being adjusted. 
           [0025]      FIG. 6  shows a perspective view of the hole being cut for the puck light. 
           [0026]      FIG. 7  shows a perspective view of a side hole being drilled to route wiring to the puck light opening. 
           [0027]      FIG. 8  shows the side hole drill entering the puck light recess hole. 
           [0028]      FIG. 9  shows a perspective view of a second preferred embodiment of the adjustable LED puck light drill jig. 
           [0029]      FIG. 10  shows a perspective view of a third preferred embodiment of the adjustable LED puck light drill jig. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0030]      FIG. 1  shows a bottom perspective view of an adjustable LED puck light drill jig  10  and  FIG. 2  shows a top perspective view of the adjustable LED puck light drill jig  10 . The adjustable LED puck light drill jig  10  has a first hole guide  20  for drilling the recess for the puck light. The hole guide  20  has a central hole  22 . The hole guide  20  is essentially rectangular is shape with vertical side walls  21 . On one or more sides of the hole guide body  20  a notch  23  or other indicia identifies the centerline of the hole  22 . This allows an installer to align the adjustable LED puck light drill jig  10  to a mark for locating the central hole  22  for the LED puck light. The body of the hole guide  20  wraps around a guide rail  40  and a portion  24  of the body of the hole guide  20  is visible on the other side of the guide rail  40 . 
         [0031]    The hole guide  20  is secured to the guide rail  40  with a nut  32  that is retained on one side of the guide rail  40  and a bolt  31  connected to a tightening knob  30  or handle that is turned to pull the nut  32  and clamp or sandwich the hole guide  20  to the guide rail  40 . The guide rail  40  is an elongated member with an elongated slot  41  that runs parallel to the sides of the guide rail  40 . The elongated slot  41  allows the hole guide  20  to be moved along the guide rail  40  to a desired distance from an edge of a shelf wall or cabinet. The location of the hole  20  can be moved and located to any position between either of two extreme ends  42  and  43  of the guide rail  40 . At one end of the guide rail  40  is a fixed guide  50  for drilling an elongated hole for to route wire to a recessed hole for a puck light that is drilled at hole  22 . 
         [0032]    The fixed guide  50  has a rectangular plate with a step having a surface  51  that is placed on the parallel surface of a shelf or cabinet where the puck light will be installed, and a vertical wall  52 , step or stop for locating the edge of the cabinet or shelf. A mark or indicia  53  identifies the centerline for drilling the wiring hole. A plurality of securing hardware members  54  secure the bottom plate  50  to the guide rail  40 . 
         [0033]    A top plate  70  is secured to the rectangular plate. Two drill guides  73  and  74  are located between the bottom plate  50  and the top plate  70 . Securing hardware  71  secures the top plate  70  to the bottom plate  50 . The securing hardware  71  allows the bottom plate  50  and the top plate  70  to be separated to replace the drill guides  73  and  74 . The top plate  70  has a clearance opening  72  for chips to be expelled from between the two drill guides  73  and  74 . The clearance opening  72  create a shorter path for removed (drilled) wood to be ejected before being transferred down the entire length of both drill guides. 
         [0034]      FIG. 3  shows a top perspective view of the adjustable LED puck light drill jig  10  in a cabinet wall or shelf and  FIG. 4  shows a top perspective view of the adjustable LED puck light drill jig  10  clamped on a shelf. When using the adjustable LED puck light drill jig  10 , the step edge surface  52  of the bottom plate  50  is brought against an edge  19  of the shelf or cabinet  100 . The adjustable LED puck light drill jig  10  is constructed in a length so the end of the guide rail  40  aligns with the far end of the cabinet or shelf  16 . While a particular length of the adjustable LED puck light drill jig  10  is shown, the length of the guide rail  40  can be fabricated in various lengths to match different size shelves or cabinets. 
         [0035]    The bottom plate  50  is aligned with the centerline  53  where the puck light will be placed. The marking location on the cabinet or shelf  100  can be pre-placed on the cabinet or shelf  100  for placement of the puck light. The handle  33  is loosened to set the location of the hole  22  along the length of the guide rail  40 . A mark  18  on the surface of the cabinet or shelf  100  is aligned with the mark or indicia  23  on the hole guide  20 . This adjustment sets the dimension  17  between the edge of the cabinet or shelf  100  and where the recessed hole  22  will be placed. The handle  33  (or a knob as previously shown) is tightened to lock the location of the hole guide  20  in the elongated slot  41  in the guide rail  40 . Once the dimensions are set, the adjustable LED puck light drill jig  10  is clamped onto the shelf or cabinet with clamps  90  and  91  at opposing sides of the adjustable LED puck light drill jig  10 . 
         [0036]      FIG. 5A  shows a cutter for a puck light with a depth stop and  FIG. 5B  shows the cutter for the cutter for a puck light with the depth being adjusted. The recessed hole is cut with a forstner or equivalent type drill. The drill has a tip  81  that creates a center guide for holding the drill or cutter in the center of the hole. One or a plurality of blades  80  cuts and clears the recessed hole. The forstner drill is placed in a guide stop having an outer guide surface  82  with a stop lip  83  that prevents the forstner drill from being pushed too far into the cabinet or shelf. The guide  82  is essentially the same dimension as the thickness of the hole guide  20  to allow the bottom lip  87  of the stop to be flush with the cabinet of shelf surface. The diameter of the guide  82  is also essentially the same as the dimension as the central hole  22  in the hole guide  20 . If a larger diameter forster drill is used the side of the guide  82  may be thinner or removed. The drill guide has a vertical circular clamp  84  that is secured  86  to the shank  85  of the forstner drill. 
         [0037]    The securing mechanism  86  is loosened to move the guide on the forstner drill to achieve the desired recess depth  101 . The guide can then be tightened to set the depth of the recess that will be drilled or cut into the shelf or cabinet. The top of the guide has openings  88  for removal of chips or sawdust as the recess is cut. The openings  88  are shown in  FIG. 6 . 
         [0038]      FIG. 6  shows a perspective view of the hole being cut for the puck light. The adjustable LED puck light drill jig  10  is shown secured to the cabinet or shelf  100  with clamps  90  and  91  on the edge  19  of the cabinet or shelf. The bottom plate  50  is shown secured to the guide rail  40 . The guide rail is secured with handle  33  clamping the hole guide  20  to the guide rail  40 . The central hole  22  has the guide  82  secured on the forstner drill shank  85  secured in drill  95  to cut a counterbore recessed hole with an essentially flat bottom. Clearance holes  88  allow removed material to clear through the forstner drill and the guide  82 . After the recessed hole is drilled the side hole for routing the electricity to the puck light can be drilled. 
         [0039]      FIG. 7  shows a perspective view of a side hole being drilled to route wiring to the puck light opening and  FIG. 8  shows the side hole drill entering the puck light recess hole. The adjustable LED puck light drill jig  10  is secured to edge  19  of the cabinet  100  with clamps  90  and  91 . The bottom plate  50  shows drill guide  74  with a drill  94  being inserted into the drill guide  74 . The drill guide  74  ensures that the drill  94  creates a hole parallel to the surface of the cabinet  100  and into the center of the center hole  22  of the hole guide  20 . Once the drill  94  enters the recessed opening for the puck light the adjustable LED puck light drill jig  10  can be removed for use in another location or the clamp arm  33  can be loosened to reposition the hole guide on the guide rail  40  to a location of the another recessed lighting hole. 
         [0040]      FIG. 9  shows a perspective view of a second preferred embodiment of the adjustable LED puck light drill jig. The jig has two plates  55  and  56  that are secured to a cabinet shelf or wall. Depressions  92  provides a location for clamping the jig onto a shelf or wall. Plate  56  slides on rods  44  to locate the hole  22  for drilling a central hole with a forstner bit. Drill guide  73  provides a guide hole for drilling the hole for wiring. While this embodiment shows two rods  44 , it is contemplated that only one or more than two rods can be used. 
         [0041]      FIG. 10  shows a perspective view of a third preferred embodiment of the adjustable LED puck light drill jig. The jig has a fixed plate  57  that mounts to one side of a shelf or wall. Drill guide  73  provides a guide hole for drilling the hole for wiring. A side rail  45  provides a guide for movable plate  58  that can be moved along rail  45  to position the location of the hole  22 . An arm  33  is turned to clamp through plate  58  and rail  45  to nut  34  to maintain the position of plate  58  relative to plate  57 . A recess  92  is used to locate a clamp to hold the jig on a shelf or wall. 
         [0042]    Thus, specific embodiments of an adjustable LED puck light drill jig have been disclosed. It should be apparent, however, to those skilled in the art that many more modifications besides those described are possible without departing from the inventive concepts herein. The inventive subject matter, therefore, is not to be restricted except in the spirit of the appended claims.