Template positioning jig

An template positioning jig. In a preferred embodiment, a deformable member is used which is deformed inwardly along a first axis such that it bulges or otherwise deforms outwardly along a second axis, until contacting the sides of a cavity, whereupon it tends to center itself within the cavity. An operably associated template is likewise centered or otherwise positioned as desired relative to the cavity.

TECHNICAL FIELD 
The present invention relates to a tool guiding apparatus and more 
particularly relates to an improved drilling template positioning jig. 
BACKGROUND OF THE INVENTION 
In the manufacture of members having an aperture therein, it is often 
desired to drill holes in the members, such that the holes are positioned 
at desired positions relative to the aperture, within acceptable 
tolerances. It is known to accomplish such manufacturing processes by the 
use of drilling templates, which are positioned as desired relative to the 
aperture prior to the drilling operation. It may be understood that 
accurate positioning of a template relative to an aperture correspondingly 
results in accurate positioning of the drilled holes relative to the 
aperture. 
It is known in the art to provide tool guiding fixtures, or "jigs", which 
may be used to position a template as desired relative to a particular 
aperture. U.S. Pat. No. 2,412,459 to Stull, entitled "TOOL GUIDING 
FIXTURE" discloses a tool guiding fixture including a template 10, a 
thumbscrew driven cam member 21 and plunger-like members 32 (see FIG. 3). 
As the thumbscrew is tightened, cam member 21 is urged upwardly, forcing 
plunger members 32 outwardly. The plunger members likewise force fingers 
38 outwardly and against the inside walls 14 of tubular part 13 such that 
template 10 is positioned as desired. 
U.S. Pat. No. 2,825,143 to Polivka, entitled "TEMPLATE CENTERING JIG" 
discloses a template centering jig including a template 10 which is 
centered along two perpendicular axes within a rectangular opening 
provided by tubing 42. Referring to FIG. 6, centering along the first axis 
is provided by threaded member 22 which, when tightened, urges actuating 
pin 34 downwardly, causing locating members 28 and 29 of the centering pin 
26 to move apart and outwardly until they engage the inner walls 40 and 41 
of the tubing 42. Centering along the second axis is provided by a 
threaded member 24 (see FIG. 4) which, when tightened, urges actuating a 
pin 56 downwardly, to urge member 53 and a similarly-shaped unnumbered 
member outwardly and against the walls of the tubing 42. 
Although the methods and apparatuses described in these patents do provide 
adequate template positioning under certain conditions, they also possess 
several different disadvantages in that they tend to be relatively 
complex, and therefore expensive, and also may tend to mar the use of 
softer metals due to metal-to-metal contact during operation. They may 
also be relatively difficult to quickly engage and disengage during 
operation, resulting in disadvantageously excessive labor costs during 
use. 
Therefore, a need has been realized to provide an improved template 
positioning jig which may be easily operated under a variety of 
conditions, does not tend to mar the surfaces of the material being 
processed and may be quickly engaged and disengaged. As always, a need 
exists to make such devices economical to produce and operate. 
SUMMARY OF THE INVENTION 
The present invention solves the above-described problems in the prior art 
by providing an improved template positioning jig construction. A template 
positioning jig according to the present invention includes the use of at 
least one deformable element, which when deformed inwardly along a first 
axis, expands along a second axis. If the deformable element is placed 
within an aperture or cavity defined at least in part by two cofacing 
sides, the element may expand to contact both surfaces and tend to seek a 
desired position between the surfaces. A template, being another component 
of the jig and operably associated with the deformable element, 
correspondingly seeks a desired position relative to the cavity. The jig 
uses a relatively small number of inexpensive moving parts, does not tend 
to mar the material being processed and is lever operated for quick 
engagement and disengagement. 
Generally described, the present invention comprises a deformable member, 
and means for deforming the deformable member inwardly along a first axis 
such that the deformable member expands outwardly along a second axis. 
More particularly described, the present invention comprises a base member 
defining a base surface, a force exerting member defining a force exerting 
surface, a deformable member positioned between the base member and the 
force exerting member, the deformable member being in contact with the 
base surface and the force exerting surface, and means for urging the 
force member relatively toward the base member along a first axis, when 
the deformable member is in the cavity, such that the deformable member is 
deformed outwardly along a second axis. 
Thus, it is an object of the present invention to provide an improved 
construction for a template positioning jig. 
It is a further object of the present invention to provide an improved 
template positioning jig that is easy to operate. 
It is a further object of the present invention to provide an improved 
template positioning jig which does not tend to mar the surface of the 
material which it contacts. 
It is a further object of the present invention to provide an improved 
template positioning jig that includes a minimum of parts, each of which 
may be readily replaced if necessary. 
It is a further object of the present invention to provide an improved 
template positioning jig which may be altered for use with elements having 
different channel widths. 
Other objects, features and advantages of the present invention will become 
apparent from reading the following specification when taken in 
conjunction with the accompanying drawings.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
For purposes of effective explanation, reference may be made herein to 
"upper", "lower", "horizontal", "vertical", "inside", "outside", etc., 
portions of various elements throughout this description. It should be 
understood that such references are merely relative terms and are made 
only in reference to the orientation of the embodiments shown in the 
accompanying figures. It is imperative to note that the preferred 
embodiments of the present invention may be used in a wide variety of 
orientations, and not only the orientation illustrated in the accompanying 
drawings. 
Referring now in more detail to the drawings, in which like numerals 
indicate like parts throughout the several views, FIG. 1 shows a template 
positioning jig 10 according to a first preferred embodiment of the 
invention, positioned in place atop a typical channel member 12 defining 
an elongate channel 14 defined in part by interior vertical cofacing sides 
16. The template positioning jig 10 includes a base which also serves as a 
template, hereinafter referred to as template 20, and also includes headed 
compression members 22, a deformable member 24, sleeve connectors 26, a 
plate 28, a pivot shaft 30, a cam 32, and an operating lever 34. 
In short summary, referring generally to FIGS. 1-5, the template 
positioning jig 10 operates as follows: the jig 10 is positioned atop a 
typical member 12 having an elongate channel 14, such that the deformable 
member 22 being generally rectangular and elongate in form is positioned 
within and along channel 16. At this time the relative positioning of the 
two members 10, 12 is as shown in FIGS. 1 and 3. The lever 34 of the 
template positioning jig 10 is then operated as shown in FIG. 4, wherein 
the lever is pivoted as indicated by arrow "A", thus operating cam 32, and 
compression members 22 are drawn upwardly by the camming action of the 
cam. Compression members 22 urge plate 28 upwardly, such that deformable 
member 24 is sandwiched between members 20, 28 and deformed inwardly along 
a substantially vertical axis. This vertical inward deformation results in 
sideward outward deformation of the deformable member 24, such that its 
sides contact the inside cofacing sides 16 defined by member 12 as shown 
in FIG. 4. This outward deformation tends to center and align the 
deformable member 24 within the channel 14, likewise tending to position 
the template 10 as desired. The lever 34 is then left in the actuated 
position shown in FIG. 4, and drilling in desired locations may be 
provided by inserting a typical drill bit (not shown) through typical 
drill guide bores 21 defined by template 20. After drilling and other 
necessary fabrication is complete, the handle 34 is retracted from its 
engaged position to its disengaged position, and may then be withdrawn 
from the member 12 to be used again in a similar manner with the same or a 
different channel member. 
A more detailed discussion of the construction and operation of the 
template positioning jig is now provided. Referring again generally to 
FIGS. 1-5, the template 20 is substantially plate-like in configuration, 
and includes an upper primary planar surface 18 and a lower primary planar 
surface 19 substantially parallel to the upper primary planar surface. 
Drill guide bores 21 are typical, extend completely through the template 
20, and have their bore axes substantially normal to the upper and lower 
primary planar surfaces of the template 20, although other orientations of 
the bore axes are contemplated under this invention. Although the use of a 
hardened plate is preferred, the drill guide bores 21 may optionally be 
defined by hardened collars, such as those known in the art, which may be 
press fit into corresponding holes defined by the template 20. In the 
preferred embodiment shown in FIG. 1, the template 20 is constructed of 
cold rolled steel, with hardening provided as necessary and as known in 
the art. 
Compression members 22 each include a head 23 (see FIGS. 2, 3) and a body 
27. In the first preferred embodiment shown in FIG. 1, compression members 
22 are typical hexagon socket machine screws. 
Referring to FIG. 5, deformable member 24 is plate-like in configuration, 
having upper and lower substantially parallel primary planar surfaces 36, 
37, respectively, and having surfaces 38, each being substantially 
perpendicular to surfaces 36, 37 and hereinafter referred to as "free" 
side surfaces 38 for reasons apparent below. Deformable member 24 is made 
of a deformable material, which in the first preferred embodiment is an 
elastomeric rubber material such a that identified in the trade as "EDPM 
80 Durometer". 
Plate 28 defines substantially parallel and upper and lower planar surfaces 
42, 43, respectively. Plate 28 likewise defines two holes 44, similar in 
orientation and spacing as holes 31 of deformable member 24. Plate 28 of 
the first preferred embodiment is made of zinc plated cold rolled steel. 
Referring now generally to FIGS. 1-5, when the template positioning jig 10 
is assembled, the elongate shafts 27 of each of the two compression 
members 22 extend through corresponding holes 44 of the plate 28, and 
likewise extend through corresponding holes 31 defined by the deformable 
member 24, such that the lower planar surface 37 of the deformable member 
24 is in planar contact with the upper planar surface 42 defined by plate 
28, and a portion of the lower planar surface 43 of plate 28 is in planar 
contact with the shoulders defined by the heads 23 of the compression 
members 22. The shafts 27 of the compression members 22 likewise extend 
through corresponding holes 17 (see FIG. 3) defined by the template 20. 
These holes 17 extend completely through the template 20 such that the 
bore axes of the holes are substantially parallel and normal to the upper 
and lower primary planar surfaces of the template 20. It may be seen that 
holes 17, 31, 44 of members 20, 24, 28, respectively, tend to be aligned 
when the compression members 22 extend through the holes. 
The threaded ends of the compression members 22, being upwardly directed in 
the orientation shown in the figures, threadably engage corresponding 
longitudinal threaded bores defined by each of the two sleeve connectors 
26, as shown in FIGS. 3, 4. As shown in FIG. 3, set screws 40 are provided 
to provide a locking feature between the compression members 22 and their 
corresponding sleeve connectors 26, as known in the art. 
As shown in FIGS. 1 and 3, the sleeve connectors 26, when attached to their 
respective compression members 22, have substantially vertical and 
coparallel longitudinal bore axes. As shown in FIG. 3, the compression 
members 22 only partially extend into the threaded bores of the sleeve 
connectors 26, thus providing clearance for an elongate substantially 
cylindrical pivot pin 30 to extend through matingly configured holes 
defined by the sleeve connectors, such that the longitudinal axis of the 
pivot pin 30 is substantially horizontal in the orientation shown in the 
figures, and substantially perpendicular to the longitudinal axis of each 
of the shafts 27 of the compression members 22. When in its assembled 
position, the ends of the pivot pin 30 fit within the sleeve connectors 
26, such that the pivot pin 30 may rotate about its longitudinal axis 
relative to the sleeve connectors 26 and the compression members 22. 
In the preferred embodiments, the sleeve connectors 26 are fabricated from 
zinc plated steel. The pivot pin 30 is preferably made of alloy steel. 
Cam member 32 is rigidly affixed by means known in the art to the pivot pin 
30, at approximately the center position of the pivot pin, such that the 
cam is positioned intermediate to the two sleeve connectors 26. A handle 
member 34 is rigidly affixed to cam member 32 by means known in the art. 
In the preferred embodiments, the handle 34 has its lower end threadably 
engaged with the cam member 32 through a corresponding threaded bore which 
connects with and is perpendicularly positioned relative to the bore which 
accepts the pivot pin 30. The threaded end of the handle 34 "locks" 
against the circumferential surface of the pivot pin 30, pursuant to 
rotation of the handle 34 until the tip of its threaded end bears against 
the pivot pin 30. 
The cam 32 is essentially disk-like in shape, and, in the preferred 
embodiments, is substantially circular, for ease of fabrication, having a 
circumferential cam surface 33 and two opposing substantially a parallel 
planar side surfaces. As discussed above, the pivot pin 30 is rigidly 
affixed to the cam 32, such that the longitudinal axis of the pivot pin 30 
is substantially normal to each of the planar surfaces of the cam 32. 
Therefore, it may be understood that the cam 32, just as the pivot pin 30, 
is free to rotate about the longitudinal axis of the pivot pin 30 relative 
to the sleeve connectors 26 and the compression members 22. Although the 
cam 32 is substantially circular in the preferred embodiments, as shown in 
FIG. 3, the longitudinal axis of the pivot pin 30 does not extend through 
the center of the cam 32, but instead has its longitudinal axis along line 
"P" spaced a distance D from the center axis of the circular-shaped cam 
along line "C". This spacing allows the cam to provide its "camming" 
action, as discussed below. 
Operation of the template positioning jig 10 according to the present 
invention is now discussed. The jig 10 is positioned relative to a typical 
channel member 12 defining a channel 14 itself defining two cofacing sides 
16, such that the deformable member 24 is positioned within the channel 
14, with each of its free sides 38 facing and closely positioned relative 
to one of the cofacing sides 16. At this time the relative positioning of 
the jig 10 and the member 12 is as shown in FIG. 1. The template 
positioning jig 10 may be understood as now being in its "unlocked" 
position. The jig 10 may now be urged into its locked position by rotating 
the handle 34 about the longitudinal axis of the pivot pin 30, in a 
direction generally shown as "A" in FIG. 4. During this action, it may be 
seen that the cam 32 provides its "camming" action, in that the cam 
surface 33 slides against the upper planar surface 18 of the template 20, 
such that the cam tends to urge the pivot pin 30 and attached sleeve 
connectors 26 and compression members 22 upwardly along an axis 
substantially parallel to the longitudinal axes of the shafts 27 of the 
compression members 22. It may be seen that this is the only direction in 
which the pivot pin 30, sleeve connectors 26, and compression members 22 
may travel, with acceptable tolerances, as the shafts 27 of the 
compression members 22 are restricted to movement along that axis due to 
the nature of the sliding engagement between the shaft 27 of the 
compression members 22 and the template 20. 
As the compression members 22 are drawn upwardly, it may be seen that they 
provide an upward force against the lower surface 43 of plate 28. 
Likewise, the plate 28 provides an upward force against the lower planar 
surface 37 of the deformable member 24. As previously discussed, the lower 
planar surface 37 of the deformable member 24 is in planar contact with 
the plate 28, and its upper planar surface 36 is in contact with the lower 
planar surface 19 of the template 20. Therefore, it may be seen that 
compression member 24 is effectively captured or "sandwiched" between the 
plate 28 and the template 20. However, it should also be understood that 
the free planar side surfaces 38 of the deformable member 24 are 
relatively unrestricted by either of members 28, 20. 
As the compression members 22 are drawn upwardly due to the camming action 
of the cam 32, it may be seen that the deformable member 24 encounters a 
force on its upper and its lower horizontal planar surfaces, which tends 
to deform it such that its free vertical sides 38 tend to bulge outwardly. 
As the free sides 38 of the deformable member 24 continue to bulge 
outwardly, eventually one bulging side will contact one of the cofacing 
sides 16 of the channel member 12. At this time, the deformable member 24 
will tend to "center" itself between the cofacing surfaces, by shifting 
toward the uncontacted cofacing surface 16, such that eventually both 
bulging sides of the deformable member are in contact with a corresponding 
cofacing surface and preferably are extending substantially equal amounts 
of horizontal force against the sides of the channel member. As the lever 
34 continues to be urged along path "A", the deformable member will 
eventually be positioned similar to that shown in FIG. 4. At this time, 
the deformable member will preferably be "centered", within acceptable 
tolerances, between the two cofacing surfaces 16 of the channel member 12. 
It may be understood that such a centering function is accomplished for 
channel members having a range of channel widths. This is an important 
feature of the invention, as channel members manufactured under relatively 
low tolerance requirements may be fabricated by use of the jig. It should 
also be understood that a second positioning function will have been 
performed besides the centering function; the deformable member will also 
have "aligned" itself along with the longitudinal axis of the channel 14, 
as the elongate free side surfaces will be preferably in full contact with 
the cofacing sides 16 defining the channel. 
As sideward motion of the deformable member 24 relative to the template 20 
is restricted by the presence of frictional forces between the members 24, 
20 and also by the tendency of compression members 22 to maintain holes 
31, 17 of the members 24, 10 in alignment, it should also be understood 
that the template will tend to move sidewardly along with the deformable 
member, with its lower planar surface 19 sliding across the top of channel 
member 12. Therefore it may be seen that as deformable member is 
positioned as desired relative to channel 14, so is template 20 positioned 
as desired relative to channel 14. 
Once the template 20 is in its desired position, drilling may be initiated 
as known in the art by use of the typical drill guides 21. The cam remains 
locked in its "engaged" position by means of friction between cam surface 
33 and upper surface 18 of template 20. 
It should be understood that although the preferred embodiment is 
configured to position the deformable member 24 at a "centered" position, 
within acceptable tolerances, other configurations may be used which, 
although not providing a "centering" function, nonetheless provide desired 
positioning of the template relative to a typical channel member 12. Such 
alternate configurations would still be capable of consistent desired 
positioning relative to channel members 12, throughout repeated operation. 
After drilling or other desired fabrication is complete, the jig 10 may be 
"disengaged" back to its position shown in FIG. 1, and may be slid along 
channel 14 to another position along the same channel member 12, or may be 
withdrawn from channel member 12 for engagement with another similar 
channel member. 
FIGS. 6-8 show a second preferred embodiment of the present invention, 
which is configured to be used with channel members 12 with channels 14 
having a greater width-to-depth ratio than that shown in FIGS. 1, 3 and 4. 
Generally described, the second preferred embodiment of the invention, 
identified as template positioning jig 60, does not include a single 
deformable member, or a plate, but instead includes two similarly-shaped 
deformable pads 62 and a pressure block 65. Referring to FIG. 8, pressure 
block 65 defines two substantially coplanar horizontal surfaces 67, two 
vertical opposing surfaces 69, and two holes 70, having substantially 
vertical and parallel axes similar in orientation to the holes described 
in conjunction with previously-discussed elements 24, 28. The pressure 
block 65 is substantially symmetrical about an axis passing through the 
center axes of holes 70. 
Referring generally to FIGS. 6-8, when the template positioning jig 60 is 
assembled, compression members 72 extend through corresponding bores 70 of 
pressure block 65, in a manner similar to the interaction of the 
compression members 22 and pressure plate 28 of previously-discussed jig 
10. However, it should be understood that compression members 72 have 
heads configured to fit flush within the pressure block due to their 
countersunk configuration. 
Contact between the deformable pads 62 and the pressure block 65 is 
maintained by means of double-sided pressure tape, gluing, or means known 
in the art. 
When the jig 60 is assembled, it may be seen, upon review of FIG. 6, that 
the lower horizontal planar surfaces of each of the deformable pads 62 are 
at least in partial contact with a corresponding one of horizontal 
surfaces 67 defined by pressure block 65. The deformable pads 62 are also 
in contact with vertical surfaces 69 of pressure block 65, such that it 
may be said that the deformable pads are "nestled" in a corner defined by 
a horizontal surface 67 cooperating with a corresponding vertical surface 
69. The upper planar surfaces of the pads 62 are in planar contact with 
the lower primary planar surface of template 20. 
Operation of jig 60 is similar to operation of previously discussed jig 10; 
the operating handle 34 is actuated such that cam 32 initiates its camming 
action, thus drawing compression members 72 upwardly. As the compression 
members 72 are urged upwardly along their longitudinal axes, they urge 
pressure block 65 in a similar direction. As pressure block 65 is urged 
upwardly toward template 20, the pressure pads 62, captured between the 
two members 20, 65, are deformed along a vertical direction. As the 
"interior" vertical sides of the pressure pads 62 are at least partially 
restrained by vertical surfaces 69 of the pressure block 65, the pads 62 
tend to bulge mostly outwardly, as shown in FIG. 7, toward a corresponding 
cofacing surface 116 of the channel 114 of member 112. As the handle 34 is 
urged toward its locked position, again the desired "centering" function 
is formed, such that the pressure block tends to be centered, within 
acceptable tolerances, within the channel 114. As the pressure block is 
relatively positioned, so is the jig 60. 
Once the jig 60 is in its engaged position, drilling operations may be 
initiated as previously discussed. Disengagement is opposite to 
engagement. 
Other embodiments are contemplated under the present invention. Referring 
to FIG. 9, two deformable members identified as deformable collars 82 may 
be used in a third embodiment of the invention shown in FIGS. 10, 11 
identified as jig 80. Each of the deformable collars 82 defines upper and 
lower planar surfaces 84, 86, respectively, and also includes a central 
bore 88. As shown in FIGS. 10, 11 each collar 82 fits around the shaft of 
a corresponding compression member 90. Operation of jig 80 is similar to 
previously-discussed jigs 10, 60 and it may be seen that each collar 82 
deforms radially to contact the sides of the typical channel member 95. 
It should be understood that the jigs embodying the present invention are 
particularly adaptable for use in fabricating channel members known as 
"mullions" which may be used in fabricating "curtainwall" constructions, 
familiar to those in the commercial window and door framing industry. Many 
mullions define channels, and it is often desired to drill holes spaced a 
desired distance relative to the center of the channels, in order to 
insert fasteners as known in the art. The present invention facilitates 
easy drilling of such holes relative to such centers, even if the widths 
of the channels vary somewhat in width. 
Thus, it may be seen that the present invention provides an effective, 
inexpensive, and reliable template positioning jig. The jig includes 
deformable members, which may be deformed along a first axis such that 
they expand a second axis. There are a minimum amount of moving parts, and 
all parts may be readily replaceable. The jig may be repeatedly locked 
onto a channel member, such that a template is consistently positioned 
relative to the cavity of a typical channel. The use of a deformable 
member is a particular advantage of the present invention, which allows 
the jig to contact metal parts without marring them, and also allows quick 
engagement and disengagement of the jig, a particular advantage if the jig 
is used in an "assembly-line" type of operation. 
It should be understood that the foregoing relates only to a preferred 
embodiment of the present invention, and that numerous modifications or 
alterations may be made therein without departing from the spirit and 
scope of the invention as set forth in the appended claims.