Electrical box layout tool

An electrical box layout tool includes a first pointed end, a first cylindrical section, a stopper, a second cylindrical section, and a second pointed end. The first cylindrical section and the second cylindrical section are concentrically connected with the stopper in such a way that the first cylindrical section and the second cylindrical section are oppositely positioned from each other. The first pointed end is concentrically connected with the first cylindrical section while the second pointed end is concentrically connected with the second cylindrical section. The electrical box layout tool is used to create an opening within a drywall or paneling so that the drywall or paneling is able to accommodate an electrical box that is mounted on a framing stud.

FIELD OF THE INVENTION

The present invention relates generally to the field of construction tools. More specifically, the present invention is an apparatus and a method that eliminates the difficult job of measuring and laying out the drywall sheets for electrical box cut outs.

BACKGROUND OF THE INVENTION

It is a common practice to cover walls and ceilings with drywall or paneling material when constructing a new residential or commercial building. The structure is first roughed in with framing members, for example, “studs”, to form walls for various areas, and for supporting wall coverings, such as the drywall or paneling. The studs are also used to hold electrical boxes that house electrical switches, receptacles, and other electrical devices. Electrical wires are strung through the framing studs to the electrical boxes. The studs are then commonly covered with drywall or paneling, where the drywall or paneling acts as the walls of the building. In order to properly install the drywall or paneling, accurate “cut outs”, matching the precise sizes and shapes of the various electrical boxes that are attached to the studs must be cut out of the drywall to accommodate the electrical boxes that must extend through the drywall or paneling. These electrical box “cut outs” can be very challenging to measure and lay out on drywall. Often, cutting errors are made during the installation of drywall or paneling, resulting in wasted material, time, and frustration.

It is the object of this invention to provide an improved method of laying out electrical box “cut outs” in drywall sheets by providing a tool that: (1) is constructed of a single piece, (2) is simple to use, (3) requires no adjustments, (4) can produce precise mirror image layouts on both sides of a drywall sheet, (5) works universally for all sizes and shapes of electrical boxes, (6) has a low manufacturing cost, (7) can locate and lay out multiple of ganged electrical boxes, (8) is small to handle and store, (9) is disposable, (10) is re-usable, (11) provides a means for producing precise electrical box “cut outs” in drywall sheets without having to measure, (12) produces “cut outs” free from breakout and roughly cut edges that may require repair or may contaminate painting rollers during the painting of the drywall.

DETAIL DESCRIPTIONS OF THE INVENTION

The present invention is an electrical box layout tool, where the present invention assists users to efficiently and precisely install a drywall sheet or paneling over electrical boxes. The present invention is a precisely shaped one piece tool that serves as an inexpensive, disposable, re-usable, simple-to-use, precise, and fool-proof device that permit the users to locate, position, and hold electrical boxes of any size or shape in place on a sheet of drywall or paneling. When a plurality of electrical box layout tools is used within a stationary electrical box6that is mounted to a framing stud, the plurality of electrical box layout tools creates shallow holes in the drywall sheet or the paneling so that the users of the present invention are able to use them to accurately outline the exact shape of the stationary electrical box6in the exact location on the drywall sheet or the paneling. The outline of the electrical box is traced in mirror image onto both sides of the drywall sheet or paneling without ever having to measure. The traced outlines are then used to make a precise electrical box opening in the drywall sheet or paneling to accommodate the electrical box mounted to framing studs. More specifically, when a plurality of electrical box layout tools is used within fastening holes7of the stationary electrical box6that is mounted to framing studs, the plurality of electrical box layout tools creates holes on the drywall sheet or the paneling so that the users of the present invention are able to accurately outline the exact shape of the stationary electrical box6on the drywall sheet or the paneling. The outlines are made on a front side91and a back side92of the drywall sheet by utilizing the present invention and at least one arbitrary electrical box8in order to cut out an opening95within the drywall sheet or the paneling, where the at least one arbitrary electrical box8is an unattached and identical electrical box that is identical to the stationary electrical box6. Then, users can align the opening95with the stationary electrical box6, exposing the stationary electrical box6through the drywall9. The present invention can be made from brightly colored plastic, metal, or any other high strength material that can withstand constant pressure applied from the drywall sheet or the paneling. Even though the electrical box layout tool is herein after described in relation to a drywall9, the electrical box layout tool can be used with many different paneling materials that are used within the construction industry.

In reference toFIG. 1andFIG. 2, the present invention comprises a first pointed end1, a first cylindrical section2, a stopper3, a second cylindrical section4, and a second pointed end5. The first cylindrical section2is adjacently and concentrically connected with the stopper3from one end. The second cylindrical section4is also adjacently and concentrically connected with the stopper3, but the second cylindrical section4is oppositely positioned from the first cylindrical section2. The first pointed end1is adjacently and concentrically connected with the first cylindrical section2opposite of the stopper3while the second pointed end5is adjacently and concentrically connected with the second cylindrical section4and oppositely positioned from the stopper3. More specifically, the first pointed end1and the second pointed end5create two shaped edges for the present invention, where the first pointed end1and the second pointed end5permit the present invention to be easily pressed into the drywall9from either direction, the first pointed end1or the second pointed end5. When the first pointed end1or the second pointed end5is pressed into the drywall9, the first cylindrical section2or the second cylindrical section4is easily traversed through the drywall9or traversed into the drywall9due to the circular shape. Since the stopper3is positioned in between the first cylindrical section2and the second cylindrical section4, the stopper3is able to limit the distance that the present invention can press into the drywall9and the fastening holes7of the stationary electrical box6. The stopper3preferably comprises a circular shape within the present invention, but the stopper3is not limited to the circular shape and can be any other geometric shape as long as the stopper3is radially extended from the first cylindrical section2and the second cylindrical section4.

In reference toFIG. 1andFIG. 2, in the preferred embodiment of the present invention, the stopper3comprises a circular shape, where the diameter of the stopper3is generally larger than the diameter of the first cylindrical section2and the second cylindrical section4. The first cylindrical section2and the second cylindrical section4are finished with a smooth outer surface41in order to minimize the pressure that needs to be applied on the drywall9. Additionally, the first cylindrical section2is shorter than the second cylindrical section4for the optimal usage of the present invention, where the length of the second cylindrical section4is longer than the thickness of any drywall9.

In reference toFIG. 3andFIG. 4, a first alternative embodiment of the present invention comprises the same components and configurations similar to the preferred embodiment, but the second cylindrical section4further comprises a plurality of flexible circular fins42. Each of the plurality of flexible circular fins42is radially and externally extended around the second cylindrical section4in such a way that each of the plurality of flexible circular fins42is positioned between the stopper3and the second pointed end5. The plurality of flexible circular fins42provides additional friction to the first alternative embodiment during different usage methods and securely retains the first alternative embodiment within the fastening holes7of the stationary electrical box6, if the second cylindrical section4is inserted into the fastening holes7of the stationary electrical box6.

In reference toFIG. 5andFIG. 6, a second alternative embodiment of the present invention comprises the same components and configurations similar to the preferred embodiment, but the second cylindrical section4further comprises a plurality of flexible linear fins43. Each of the plurality of flexible linear fins43is radially and externally extended along the second cylindrical section4in such a way that each of the plurality of flexible linear fins43is positioned in between the stopper3and the second pointed end5. Similar to the first alternative embodiment, the plurality of flexible linear fins43provides additional friction to the second alternative embodiment during different usage methods and securely retains the second alternative embodiment within the fastening holes7of the stationary electrical box6, if the second cylindrical section4is inserted into the fastening holes7of the stationary electrical box6.

The electrical box layout tools are divided into the first cylindrical section2and the second cylindrical section4by the stopper3, where the first cylindrical section2is the shorter section, and the second cylindrical section4is the longer section. The longer section of each of the plurality of electrical box layout tools, which may contain the plurality of flexible linear fins43or the plurality of flexible circular fins42, is pressed within each of the fastening holes7of the stationary electrical box6that is mounted to the framing studs of a room, until the stopper3contacts the face of the fastening holes7. In so doing, the plurality of flexible linear fins43or the plurality of flexible circular fins42of the present invention, which permits the present invention to fit slightly varying hole sizes, is compressed and/or deformed, causing outward pressure against the side wall of the fastening holes7. This securely holds the plurality of electrical box layout tools firmly in place, such that the shorter section of each of the plurality of electrical box layout tools is extended outwardly from the fastening holes7. Further, the drywall9is placed in position, one at a time, at the position where they are to be attached to the framing studs and against the plurality of electrical box layout tools and extending out from the fastening holes7. Now, hand pressure is applied to the face of the drywall9at the location of each of the stationary electrical boxes6, causing the plurality of electrical box layout tools to puncture the back side92of the drywall9, producing a plurality of shallow holes93approximately ¼ to ½ inch deep. The drywall9is then removed, exposing all of the plurality of shallow holes93.

The plurality of shallow holes93are precisely drilled through the drywall9using a drill guide12, which is cylindrically shaped, and made of wood, plastic or metal. It has a precision hole through its center that will guide a drill bit passing through it at precisely 90 degrees to its face.

To drill the plurality of shallow holes93through the drywall9, a drill bit clamped in a hand drill is passed through the center hole of the drill guide12. The end of the drill bit is then located in one of the plurality of shallow holes93made in the back side92of the drywall9by the plurality of electrical box layout tools. The drill guide12is then pressed firmly against the surface of the drywall9. This causes the drill bit to be precisely aligned 90 degrees to the back side92of the drywall9. A precisely located, drilled hole is then drilled through the drywall9. A slightly larger hole that comprises a larger diameter than the diameter of the plurality of electrical box layout tools is drilled through the drywall9, to accommodate the plurality of flexible circular fins42or the plurality of flexible linear fins43. In like manner, precisely located drilled holes, 90 degrees to the drywall9are drilled at each of the plurality of shallow holes93that is punched in the back side92of the drywall9. Next, the plurality of electrical box layout tools that made the plurality of shallow holes93is removed from the stationary electrical boxes6, and the second cylindrical sections4are now placed into the drilled holes and are pressed completely through the drywall9until the stopper3contacts the drywall9surface. The plurality of electrical box layout tools is now protruding out from both sides of the drywall9and is held snugly in place by the force of the plurality of flexible circular fins42or the plurality of flexible linear fins43pressing outward against the side wall of the drilled holes. These drilled holes are herein after described as a plurality of guide openings94.

The fastening holes7in at least one arbitrary electrical box8identical to the ones mounted to the framing studs are now fit, one at a time, onto the plurality of electrical box layout tools extend out from the back side92of the drywall9. Next, the arbitrary electrical boxes8that are guided by the plurality of electrical box layout tools are pressed tight against the drywall9surface, where they are precisely positioned and held in place by the plurality of electrical box layout tools. Each shape of the arbitrary electrical boxes8is then outlined or traced with a marking pen onto the drywall9, producing the precise layout lines required to make the opening95, to fit the electrical boxes6. In like manner, by means of the plurality of electrical box layout tools, extending out from the front side91of the drywall9, each shape of the arbitrary electrical boxes8is precisely located and outlined onto the front side91of the drywall9, creating precise mirror image layouts of the electrical boxes6. The outlines are then used as guides, and the openings95are now precisely made by cutting on the electrical box outlines, using a utility knife to cut slightly deeper than the thickness of the paper surfaces of the drywall9, on both sides. The openings95are then completed by knocking out the center of the electrical box layout with a light hammer blow at the center of the layout.

The openings95, due to being cut on both sides of the drywall9, are precise and free from the breakout, rough edges, and loose drywall particles that commonly contaminate paint rollers when the openings95of the installed drywall9are rolled over during painting of the drywall9.

These improved methods of producing the openings95are expedient, simple, precise and error-proof. They eliminate the frustrating, costly errors resulting in wasted material and time, due to incorrect measurements.

In reference toFIG. 7-FIG. 10, in the first method of using the present invention, the plurality of electrical box layout tools is inserted into the fastening holes7of the stationary electrical box6. More specifically, the second cylindrical sections4are inserted into the fastening holes7of the stationary electrical box6in such a way that only the first cylindrical sections2are externally extended from the fastening holes7of the stationary electrical box6. For example, if the stationary electrical box6includes four fastening holes7, the second cylindrical sections4of the four electrical box layout tools are inserted into the four fastening holes7so that only the first cylindrical sections2of the four electrical box layout tools are externally extended from the fastening holes7of the stationary electrical box6. Then the back side92of the drywall9is pressed against the plurality of electrical box layout tools and the framing stud in order to create the plurality of shallow holes93within the drywall9. More specifically, the first cylindrical sections2are pressed into the back side92of the drywall9as the users apply hand pressure to the front side91of drywall9, where the pressure is applied at the location of the stationary electrical box6. Then, the drywall9is removed away from the framing stud and the stationary electrical box6. Upon removing the drywall9, the users have to inspect the positioning of the plurality of electrical box layout tools so that a first outline10can be traced in the back side92of the drywall9.

In reference toFIG. 7, if the plurality of electrical box layout tools is positioned within the fastening holes7of the stationary electrical box6, the users are able to visually identify the plurality of shallow holes93. Then the users can drill through the plurality of shallow holes93from the back side92of the drywall9in order to create the plurality of guide openings94. Then the plurality of electrical box layout tools is removed from the fastening holes7of the stationary electrical box6, and the second cylindrical sections4of the plurality of electrical box layout tools are inserted into the plurality of guide openings94from the back side92of the drywall9. More specifically, the second cylindrical sections4are inserted through the plurality of guide openings94so that the first cylindrical sections2are able to extend from the back side92of the drywall9and the second cylindrical sections4are able to extend from the front side91of the drywall9. Then the at least one arbitrary electrical box8is engaged with the first cylindrical sections2in order to trace the first outline10.

In reference toFIG. 9, if the plurality of electrical box layout tools is positioned with the drywall9, the users are not able to visually identify the plurality of shallow holes93. Therefore, the users have to remove the plurality of electrical box layout tools from the drywall9. After removing the plurality of electrical box layout tools from the drywall9, the plurality of shallow holes93is drilled from the back side92of the drywall9in order to create the plurality of guide openings94through the drywall9. Then the second cylindrical sections4of the plurality of electrical box layout tools are inserted into the plurality of guide openings94from the back side92of the drywall9. More specifically, the second cylindrical sections4are inserted through the drywall9so that the first cylindrical sections2are able to extend from the back side92of the drywall9and the second cylindrical sections4are able to extend from the front side91of the drywall9. Then the at least one arbitrary electrical box8is engaged with the first cylindrical sections2in order to trace the first outline10.

Once the first outline10is drawn on to the back side92of the drywall9, the at least one arbitrary electrical box8is engaged with the second cylindrical sections4extending from the front side91of the drywall9so that the second outline11can be traced on to the drywall9creating a mirror-image layout to the first outline10. Then the drywall9is cut through the first outline10and the second outline11in order to create the opening95through the drywall9.

In reference toFIG. 11-FIG. 14, in the second method of using the present invention, the plurality of electrical box layout tools is inserted into fastening holes7of the stationary electrical box6. More specifically, the first cylindrical sections2are inserted into the fastening holes7of the stationary electrical box6in such a way that only the second cylindrical sections4are externally extended from the fastening holes7of the stationary electrical box6. Then the back side92of the drywall9is pressed against the plurality of electrical box layout tools, forcing the electrical box layout tool's cylindrical section4, to traverse through the drywall9from the back side92as the users apply hand pressure to the front side91of drywall9, where the pressure is applied at the location of the stationary electrical box6. Due to the fact the second cylindrical sections4traverse through the drywall9, the second cylindrical sections4create the plurality of guide openings94through the drywall9. Then the drywall9is removed away from the framing stud and the stationary electrical box6. Upon removing the drywall9, the users have to inspect the positioning of the plurality of electrical box layout tools so that the first outline10can be traced in the back side92of the drywall9.

In reference toFIG. 11, if the plurality of electrical box layout tools is positioned within the plurality of guide openings94of the drywall9, the at least one arbitrary electrical box8is engaged with the first cylindrical sections2in order to trace the first outline10. Since the first cylindrical sections2are externally extended from the back side92of the drywall9, the user can easily engage the at least one arbitrary electrical box8with the first cylindrical sections2to trace the second outline11.

In reference toFIG. 13, if the plurality of electrical box layout tools is positioned within the fastening holes7of the stationary electrical box6, the users are able to identify only the plurality of guide openings94within the drywall9. Then the plurality of electrical box layout tools is removed from the fastening holes7of the stationary electrical box6, and the second cylindrical sections4of the plurality of electrical box layout tools are inserted into the plurality of guide openings94from the back side92of the drywall9. More specifically, the second cylindrical sections4are inserted through the drywall9so that the first cylindrical sections2are able to extend from the back side92of the drywall9and the second cylindrical sections4are able to extend from the front side91of the drywall9. Then the at least one arbitrary electrical box8is engaged with the first cylindrical sections2in order to trace the first outline10.

Once the first outline10is drawn within the back side92of the drywall9, the at least one arbitrary electrical box8is engaged with the second cylindrical sections4from the front side91of the drywall9so that the second outline11can be traced within the drywall9. Then the drywall9is cut through the first outline10and the second outline11in order to create the opening95within the drywall9.

As for the third method of using the present invention, the plurality of electrical box layout tools is inserted into fastening holes7of the stationary electrical box6. More specifically, the first cylindrical sections2are inserted into the fastening holes7of the stationary electrical box6in such a way that only the second cylindrical sections4are externally extended from the fastening holes7of the stationary electrical box6. Then the back side92of the drywall9is pressed against the plurality of electrical box layout tools and the framing stud in order to force the second cylindrical sections4to traverse through the drywall9from the back side92as the users apply hand pressure to the front side91of drywall9, where the pressure is applied at the location of the stationary electrical box6. The second cylindrical sections4are traversed through the drywall9, creating the plurality of guide openings94, and extend from the front side91of the drywall9. Now, the at least one arbitrary electrical box8is engaged with the second cylindrical sections4in order to trace only the second outline11. Then the drywall9is cut through the second outline11to create the opening95within the drywall9while the drywall9is adjacently positioned with the framing stud and the stationary electrical box6.

Although the invention has been explained in relation to its preferred embodiment, it is to be understood that many other modifications and variations can be made without departing from the spirit and scope of the invention as herein after claimed.