Abstract:
A door hardware locating tool includes a first side wall having a first side, a second side opposite, and a cavity defined between the first and second sides. The door hardware locating tool further includes a second side wall coupled to the first side wall and extending substantially parallel to the first side wall, a center wall disposed between the first and second side walls, a clamping mechanism operable to clamp a door between the first and second side walls, and an insert at least partially located within the cavity and translatable along the first side wall between a first position and a second position. The insert includes an aperture sized to receive a cutting tool. In the first position, the aperture is located a first backset distance from the center wall, and in the second position, the third aperture is located a second backset distance from the center wall.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to co-pending U.S. Provisional Patent Application No. 61/834,313 filed on Jun. 12, 2013, the entire content of which is incorporated herein by reference. 
    
    
     BACKGROUND 
     The present invention relates to a locating tool, and more particularly to a door hardware locating tool for correctly positioning an edge bore and a cross bore in a door for the installation of a door lock, a door latch and knob assembly, or a deadbolt. 
     Installing door hardware, such as a door lock, a door latch and knob assembly, or a deadbolt assembly, is often a time consuming operation. First, it is necessary to mark the location of the various holes and recesses on the side and edge of the door into which the lock assembly will be fitted. Using these markings, various tools can be employed to create an edge bore in the edge of the door. In addition, a cross bore must be drilled through the door perpendicular to the edge bore at an appropriate distance from the edge of the door (often referred to as backset). When installing numerous door lock assemblies, such as in a building construction or refurbishment project, it is desirable to fit all the lock assemblies in their respective doors at a consistent height and position throughout the building. In addition, it is desirable for the installation process to be as quick, efficient, and accurate as possible. 
     SUMMARY 
     In one embodiment, the invention provides a door hardware locating tool including a first side wall having a first side with a first aperture, a second side opposite the first side, the second side with a second aperture, and a cavity defined between the first and second sides. The door hardware locating tool further includes a second side wall coupled to the first side wall and extending substantially parallel to the first side wall, a center wall disposed between the first and second side walls, a clamping mechanism operable to clamp a door between the first side wall and the second side wall, and an insert at least partially located within the cavity and translatable along the first side wall between a first position and a second position. The insert includes a third aperture sized to receive a cutting tool. In the first position, the third aperture is located a first backset distance from the center wall and the first aperture, the second aperture, and the third aperture are aligned to provide a pathway for the cutting tool through the first side wall. In the second position, the third aperture is located a second backset distance from the center wall and the first aperture, the second aperture, and the third aperture are aligned to provide a pathway for the cutting tool through the first side wall. 
     In another embodiment, the invention provides a locating tool for correctly positioning an edge bore and a cross bore in a door for the installation of door hardware. The locating tool includes a first wall, a second wall, an edge wall, and a clamping mechanism. The clamping mechanism interconnects the first wall, the second wall, and the edge wall. The clamping mechanism is operable to selectively clamp the door between the first wall and the second wall. The locating tool further includes an alignment marking to facilitate positioning of the locating tool on the door. The alignment marking includes a horizontal groove extending along at least a portion of the first wall, the second wall, and the edge wall. An insert is slidably positioned in the first wall and is movable between a first position for positioning the cross bore at a first backset distance and a second position for positioning the cross bore at a second backset distance. At least one of the insert and the first wall includes a slot for facilitating egress of dust or debris produced during formation of the cross bore. 
     In yet another embodiment, the invention provides a kit for correctly positioning and forming an edge bore and a cross bore in a door for the installation of door hardware. The kit includes a locating tool, a hole saw, and a hole saw plug. The hole saw plug is insertable into the hole saw to limit a cutting depth of the hole saw. Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a portion of a door. 
         FIG. 2  is a perspective view of a door hardware locating tool, according to an embodiment of the invention, for facilitating the installation of door hardware on the door of  FIG. 1 . 
         FIG. 3  is an exploded view of the tool of  FIG. 2 . 
         FIG. 4  is a perspective view of the tool of  FIG. 2 , with an insert in a first position to provide a first backset distance. 
         FIG. 5  is a perspective view of the tool of  FIG. 2 , with the insert in a second position to provide a second backset distance. 
         FIG. 6  is a cross-sectional view of the insert of  FIGS. 4 and 5 . 
         FIG. 7  is a cross-sectional view of a portion of the tool of  FIG. 2 , taken through line  7 - 7  of  FIG. 2 . 
         FIG. 8  is another perspective view of the tool of  FIG. 2 . 
         FIG. 9  is a cross-sectional view of the tool of  FIG. 2 , taken through line  9 - 9  of  FIG. 2 . 
         FIG. 10  is a perspective view of a hole saw and a hole saw plug usable with the tool of  FIG. 2 . 
         FIG. 11  is another perspective view of the hole saw plug of  FIG. 10 . 
     
    
    
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a portion of a door  10  into which door hardware, such as a door lock, a door latch and knob assembly, or a deadbolt assembly, may be installed. Installing the door hardware requires an edge bore  14  (also referred to as a latch bore) to be drilled into a latch edge  18  of the door  10  and a cross bore  22  to be drilled through the door  10  through a first side  26  and a second side  30  of the door  10 . An edge bore axis  34  extends through a center point of the edge bore  14 , and a cross bore axis  38  extends through a center point of the cross bore  22 . The edge bore axis  34  is substantially normal to and coplanar with the cross bore axis  38 . The edge bore  14  intersects the cross boor  22  inside the door  10 . When properly positioned, the plane containing the edge bore axis  34  and the cross bore axis  38  will be substantially perpendicular to the latch edge  18 . The edge bore  14  is centered along a width  42  of the latch edge  18 . Typical doors  10  have a latch edge width  42  between 1⅜ inches and 1¾ inches. A backset  46  (i.e., the distance from the latch edge  18  to the center point of the cross bore  22 ) is typically 2⅜ inches or 2¾ inches, depending on the door hardware. The edge bore  14  and the cross bore  22  must also be properly positioned vertically on the door  10 . For example, for a door  10  having a height of 80 inches, it may be desirable to position the centers of the edge bore  14  and cross bore  22  at a height of about 36 inches. A door hardware locating tool is used to ensure that the edge bore  14  and the cross bore  22  are properly positioned on the door  10 . 
       FIG. 2  illustrates a door hardware locating tool  100  according to an embodiment of the invention. The tool  100  includes an edge wall or center wall  104 , a first wall  108 , a second wall  112 , and a clamping mechanism  116 . The first wall  108  and the second wall  112  are coupled to the edge wall  104  by the clamping mechanism  116 , which will be described in greater detail below. The first wall  108  and the second wall  112  extend substantially perpendicularly from the edge wall  104 . In the illustrated embodiment, the walls  104 ,  108 ,  112  are made of plastic, with other materials also being suitable. 
     With continued reference to  FIG. 2 , the edge wall  104  includes a first side  120 , a second side  124  opposite the first side  120 , and an edge bore aperture  128  extending through the first and second sides  120 ,  124 . The edge bore aperture  128  functions as an edge bore locator, and the center of the edge bore aperture  128  defines an edge bore axis  132 . The edge bore aperture  128  is circular and is centered in the edge wall  104 . The edge bore aperture  128  is sized to receive a cutting tool, such as a hole saw or a drill bit, that is the proper size for the latch bore  14 . In other embodiments, the edge bore aperture  128  could be larger than the desired latch bore size, and adapters that match standard latch bore sizes could be provided for insertion into the aperture  128 . 
     With reference to  FIG. 3 , the first wall  108  includes a first side  136 , a second side  140  opposite the first side  136 , and top and bottom sides  144 ,  148  extending between the first and second sides  136 ,  140 . The second wall  112  includes a first side  152  generally facing the first wall  108  and a second side  156  opposite the first side  152 . 
     An oval-shaped aperture  160  extends through the first side  136  of the first wall  108 , and a generally rectangular aperture  164  extends through the second side  140 . A portion of the first wall is substantially hollow to define a cavity  168  between the sides  136 ,  140 ,  144 ,  148 . An insert  172  having a cross bore aperture  178  is received within the cavity  168  such that the cross bore aperture  178  is aligned with the oval-shaped aperture  160  and the rectangular aperture  164  to provide a pathway through the first wall  108 . The cross bore aperture  178  functions as a cross bore locator, and the center of the cross bore aperture  178  lies on a cross bore axis  182 . The cross bore axis  182  is substantially normal to and coplanar with the edge bore axis  132 . The cross bore aperture  178  is sized to receive a cutting tool, such as a hole saw or a drill bit, that is the proper size for the cross bore  22 . In other embodiments, the cross bore aperture  178  could be larger than the desired cross bore size, and adapters that match standard cross bore sizes could be provided for insertion into the aperture  178 . 
     With reference to  FIGS. 4 and 5 , the insert  172  is slidable within the cavity  168  between a first position and a second position to adjust the position of the cross bore aperture  178  and therefore, the backset distance  46 . In the illustrated embodiment, the cross bore axis  182  is spaced about 2⅜ inches from the second side  124  of the edge wall  104  when the insert  172  is in the first position ( FIG. 4 ). This corresponds with a backset distance  46  of 2⅜ inches (6.03 centimeters) when the tool  100  is properly positioned on the door  10  of  FIG. 1 . When the insert  172  is in the second position ( FIG. 5 ), the cross bore axis  182  is spaced about 2¾ inches from the second side  124  of the edge wall  104 , corresponding with a backset distance  46  of 2¾ inches when the tool  100  is properly positioned on the door  10  of  FIG. 1 . 
     With reference to  FIG. 6 , the tool  100  includes an actuator  190  coupled to the insert  172  to facilitate sliding the insert  172  between the first and second positions. In the illustrated embodiment, the actuator  190  includes tabs  194  received by the insert  172  in a snap-fitting manner to secure the actuator  190  to the insert  172 . In other embodiments, the actuator  190  can be coupled to the insert  172  by other inter-engaging means or fasteners. Alternatively, the actuator  190  can be integrally formed with the insert  172 . Referring to  FIG. 7 , the actuator  190  includes a pair of resilient members  198 , and the first wall  108  includes a first pair of recesses  202  and a second pair of recesses  206 . Each of the resilient members  198  is configured as a leaf spring having a projecting portion  210  selectively engageable with the first and second recesses  202 ,  206 . In the illustrated embodiment, the projecting portions  210  engage the first recesses  202  when the insert  172  is in the first position and engage the second recesses  206  when the insert is  172  in the second position. This engagement positively positions the insert  172  and the actuator  190  in the first and second positions to provide consistent and accurate positioning of the cross bore aperture  178 . In other embodiments, the actuator  190  can include other positive positioning arrangements, such as a detent arrangement. 
     With reference again to  FIGS. 4 and 5 , the insert  172 , the actuator  190 , and/or the first wall  108  can include indicia for indicating to a user of the tool  100  whether the insert  172  is in the first position or the second position. In the illustrated embodiment, the insert  172  includes a first indicium  214  visible through an opening  218  in the top side  144  of the first wall  108  when the insert  172  is in the first position and a second indicium  222  visible through the opening  218  when the insert  172  is in the second position. In addition, the actuator  190  includes an arrow  226  that aligns with arrows  230  on the first wall  108  when the insert  172  is in the first position and the second position, respectively. 
     With reference to  FIGS. 3 and 8 , the insert  172  includes a plurality of slots  234  extending from the cross bore aperture  178  through the bottom of the insert  172 . The first wall  108  includes a plurality of slots  238  extending through its bottom side  148 . The slots  234  of the insert  172  are generally aligned with the slots  238  of the first wall  108  to permit egress of sawdust and other debris generated during creation of the cross bore  22 . 
     The clamping mechanism  116  will now be described with reference to  FIGS. 3 and 9 . The clamping mechanism  116  includes first and second, vertically-spaced rods  242 ,  246  that extend through the first wall  108 , edge wall  104 , and second wall  112  to couple the walls  108 ,  104 ,  112  together. The first rod  242  is a threaded rod and is threadably engaged with a first bushing  250  supported within the first wall  108  and a second bushing  254  supported within the second wall  112 . The second rod  246  is as a non-threaded rod and is slidably engaged with a third bushing  258  supported within the first wall  108  and a fourth bushing  262  supported within the second wall  212 . Each of the rods  242 ,  246  is axially fixed within the edge wall  104  such that the rods  242 ,  246  remain centered relative to the edge wall  104 . In the illustrated embodiment, each of the rods  242 ,  246  includes a groove  264  that receives a snap ring  268  to axially fix the rods  242 ,  246  within the edge wall  104  while permitting the rods  242 ,  246  to rotate relative to the edge wall  104  ( FIG. 9 ). In other embodiments, the rods  242 ,  246  can include a shoulder received in a corresponding recess of the edge wall  104 , or any other suitable arrangement for axially fixing the rods  242 ,  246  within the edge wall  104 . 
     With continued reference to  FIGS. 3 and 9 , the first bushing  250  includes right-hand threads and the second bushing  254  includes left-hand threads. Alternatively, the first bushing  250  can include left-hand threads and the second bushing  254  can include right-hand threads. The first and second bushings  250 ,  254  include opposite thread orientations so that rotation of the first rod  242  causes translation of the first and second walls  108 ,  112  in opposite directions. For example, rotation of the first rod  242  in a first direction  272  (e.g., clockwise) causes the first and second walls  108 ,  112  to move towards each other, allowing the tool  100  to be securely clamped on to the door  10 . Rotation of the first rod  242  in a second direction  276  (e.g., counterclockwise) causes the first and second walls  108 ,  112  to move away from each other, allowing the tool  100  to be removed from or repositioned on the door  10 . The first and second bushings  250 ,  254  have the same thread pitch. Therefore, the first and second walls  108 ,  112  move towards/away from each other at the same rate relative to the edge wall  104  to automatically center the edge bore  128  when the tool  100  is positioned on a door  10 . A knob  280  is coupled to an end  284  of the first rod  242  to facilitate rotation of the first rod  242 . 
     Referring again to  FIG. 2 , the tool  100  includes alignment markings  288  to facilitate proper positioning of the tool  100  on the door  10 . In the illustrated embodiment, the alignment markings  288  include a vertical groove  292  extending along the center of the edge wall  104  and a horizontal groove  296  extending along the center of the first wall, the edge wall, and the second wall. A portion of the horizontal groove  296  is located in the oval-shaped aperture  160  and the cross bore aperture  178 . In other embodiments, the alignment markings  288  may include printed markings (e.g., lines) to facilitate proper positioning of the tool  100  on the door  10 . 
       FIG. 10  illustrates a hole saw  300  usable with the door hardware locating tool  100  of  FIGS. 2-9  to create the cross bore  22  in the door  10  of  FIG. 1 . The hole saw  300  includes a hollow, cylindrical body  304  having a bottom wall  308 , and teeth  312  extending axially from the body  304 . The hole saw  300  is able to cut to a depth  316  limited by an axial distance between the teeth  312  and the bottom wall  308 . In some cases, the depth  316  is greater than the edge width  42  of the door  10 , and the hole saw  300  could create the cross bore  22  in a single pass (e.g., from the first side  26  of the door  10  to the second side  30 ). This may cause the backside (e.g., the second side  30 ) of the door  10  to chip or splinter. A hole saw plug  400  can be inserted into the body  304  of the hole saw  300  to act as a depth stop (i.e., the hole saw plug  400  reduces the maximum cutting depth  316  of the hole saw  300 ). The plug  400  prevents a user from drilling entirely through the door  10 , forcing the user to drill from both sides  26 ,  30  of the door  10  to complete the cross bore  22 . With reference to  FIGS. 10 and 11 , the plug  400  includes a cylindrical body  404  having a central aperture  412  and projections  408  that engage with corresponding apertures (not shown) in the bottom wall  308  of the hole saw  300  to retain the plug  400  within the hole saw  300 . In some embodiments, the door hardware locating tool  100 , the hole saw  300 , and the plug  400  may be included together as a kit. 
     In use, a user first measures a desired height of the door hardware to be installed, and marks the desired height on the door  10 . Next, the user selects the appropriate backset distance  46  for the cross bore  22  by manipulating the actuator  190  to slide the insert  172  to the first position ( FIG. 4 ) or to the second position ( FIG. 5 ). The user then positions the door hardware locating tool  100  so that the second side  124  of the edge wall  104  abuts the latch edge  18  of the door  10 , and the horizontal groove  296  is aligned with the desired height mark. 
     Once the tool  100  is properly positioned, the user tightens the clamping mechanism  116  by rotating the knob  280  and therefore, the first rod  242 , in the first direction  272  ( FIG. 3 ). The first and second sides  26 ,  30  of the door  10  are clamped between the first sides  136 ,  152  of the first and second walls  108 ,  112  of the tool  100  ( FIGS. 1 and 3 ). Because the first and second walls  108 ,  112  move towards each other at the same rate, the latch bore aperture  128  is automatically centered on the latch edge  18  of the door  10  as the clamping mechanism  116  is tightened. 
     To cut the edge bore  14  in the latch edge  18 , the user inserts a cutting tool into the edge bore aperture  128  and proceeds to cut a hole into the latch edge  18  ( FIGS. 1 and 2 ). The edges of the cutting tool contact the edge bore aperture  128  to correctly position the edge bore  14  on the latch edge  18 . 
     To cut the cross bore  22  through the door  10 , the user inserts the hole saw  300  (or another cutting tool) into the cross bore aperture  178  and proceeds to cut a hole through the door  10  ( FIGS. 1 ,  2 , and  10 ). The edges of the hole saw  300  contact the cross bore aperture  178  to correctly position the cross bore  22  through the door sides  26 ,  30 . Creating the cross bore  22  creates sawdust which is able to fall away from the cross bore  22  through the slots  238 ,  238 . If the user employs the hole saw plug  400  to prevent the hole saw  300  from cutting all the way through the door  10  in a single pass, the user can flip the tool  100  and reposition the tool  100  on the door  10  so that the cross bore aperture  178  is aligned with the partially-formed cross bore  22  on the opposite side of the door  10 . The user then inserts the hole saw  300  into the cross bore aperture  178  and proceeds to cut the cross bore  22  through the remaining portion of the door  10 . Once the cross bore  22  and the edge bore  14  have been formed, the user loosens the clamping mechanism  116  to remove the tool  100  from the door  10 . 
     Various features of the invention are set forth in the following claims.