Abstract:
A lockset drilling guide and a method of forming holes in a door are provided. The drilling guide includes a frame and at least a first opening and a second opening defined in the frame. The first opening is positioned at approximately 90 degrees to the second opening. The frame is configured for positioning on a door to facilitate the forming of openings in a door for the installation of a lockset. The method includes the steps of providing a frame having at least a first opening and a second opening defined in the frame; positioning the frame on an edge of the door; inserting a first holesaw at least particularly into the first opening and drilling a first hole in the door; inserting a second holesaw at least partially into the second opening and drilling a second hole in the door; and removing the frame from the door.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application is a continuation of patent application Ser. No. 10/629,959, filed Jul. 30, 2003, entitled “Lockset Drilling Guide” and U.S. application Ser. No. 60/407,485, filed Aug. 30, 2002, which are both incorporated herein in their entirety by reference and are assigned to the same assignee as this application. 
     
    
     BACKGROUND OF INVENTION  
       [0002]     The present invention relates to carpentry tools. In particular, the present invention relates to a drilling guide for facilitating the drilling of holes in a door for the installation of standard locksets.  
         [0003]     Standard-sized door handle locksets are used to latch and secure hinged doors to a doorjamb-mounted strikeplate. These locksets typically require the drilling of a large, throughgoing hole in the face of the door and a perpendicularly-extending, smaller hole in the edge of the door. Additional holes must be drilled in the edge of the door to retain the latchplate. The lockset and door handles are mounted to both sides of the larger hole, and the latchplate and cylinder latch are mounted to the smaller hole on the edge of the door.  
         [0004]     Typically, the center of the larger hole, which is located in the face of the door, must be either 2⅜ or 2¾ inches from the edge of the door, depending on the type of brand of lockset to be installed. To facilitate the drilling of the holes in the door, most of such locksets include a paper template that the installer may affix to the door to mark the drilling holes for the lockset.  
         [0005]     These paper templates have significant shortcomings, however. First, the non-durable templates must be taped to the door, and this may become a tedious task for carpenters who are charged with installing many locksets at a jobsite. Furthermore, because of the stretching of the template or the possibility of misaligning it on the door with the wrong marking line, it is very possible that one or more of the holes may be marked in the wrong location. The fact that interior doors typically are configured in at least two popular thicknesses (1⅜″ and 1¾″) adds to the difficulty in accurately positioning the template. In addition to these problems with the template, it is often difficult to drill holes in the door edge and face that are perfectly aligned with their central axes perpendicular to each other. Such misalignment or misplacement may result in a poorly fitting lockset or a lockset that fails to properly engage the strikeplate on the doorjamb. At worst, an entire door can be ruined and may need to be completely discarded if the holes are drilled improperly.  
         [0006]     A particularly inexperienced user may even use the wrong size holesaw or paddle bit when using either of these templates methods, thereby resulting in a large hole of an incorrect size. If the hole is too small for the lockset yet too large for the pilot drill of a holesaw, it may be impossible for the proper sized holesaw to enlarge the hole accurately on center of the previous hole. A similar problem will arise when enlarging a preexisting lockset hole in a previously drilled door, in that it is extremely difficult to center the larger holesaw over the center of a preexisting hole. Because newer locksets typically require a 2⅛ inch hole in the face of the door instead of the previously popular 1⅞ inch hole, this has become an increasing problem.  
         [0007]     In the past, some have attempted to solve some of the inaccuracy problems in lockset installation through the use of a more durable plastic template that allows the drilling of pilot holes in the door. Such a template is shown in U.S. Pat. No. 4,280,776. While the plastic template disclosed therein may have some advantages over a paper template, the tool is still prone to most of the inaccuracy problems discussed above. Furthermore, by only allowing the marking or drilling of pilot holes, additional time-consuming steps must be taken in preparing and drilling each door.  
       BRIEF SUMMARY OF THE INVENTION  
       [0008]     In order to address one or more of the shortcomings discussed above, a lockset drilling guide is provided herein. In one embodiment and one aspect of the invention, a frame is provided having a first opening and a second opening. The first opening is positioned at approximately 90 degrees to the second opening. The frame is configured for positioning on a door to facilitate the forming of openings in the door for the installation of a lockset.  
         [0009]     In another embodiment of the invention, a drilling guide having an angular frame for positioning along the edge of a door is provided. The frame includes at least a first and a second opening defined in the frame wherein the openings are positioned relative to each other to guide the drilling of a corresponding first and second set of holes in a door having perpendicularly extending axes. The frame comprises at least one spacing tab mountable to the drilling guide, each of the at least one tabs is flexibly attached to the frame via at least one strap.  
         [0010]     Another embodiment of the present invention includes a drilling guide with an L-shaped frame for positioning along the edge of a door. A first cylindrical opening is defined in the frame having a first axis and second cylindrical opening is defined in the frame having a second axis. The first and second axes intersect at approximately 90 degrees to each other. The openings are configured to guide correspondingly sized holesaws for forming holes in the door. The drilling guide includes at least one spacing tab for spacing the frame a predefined distance from the door.  
         [0011]     Another embodiment of the present invention includes a drilling guide having an L-shaped frame having a first flange and a second flange mounted perpendicularly thereto. The flanges define first and second rear faces. A First circular opening is defined in the first flange, the first opening includes a first annular lip and a second circular opening is defined in the second flange, the second opening including a second annular lip. A plurality of spacing tabs are flexibly attached to the frame, the tabs being removably mountable to the rear faces.  
         [0012]     In another embodiment of the present invention, a method is provided for forming holes in a door. The method comprises the steps of providing a frame having at least a first opening and a second opening defined in the frame, the first opening being positioned at approximately 90 degrees to the second opening; positioning the frame on an edge of the door; inserting a first holesaw at least partially into the first opening and drilling a first hole in the door; inserting a second holesaw at least partially into the second opening and drilling a second hole in the door; and removing the frame from the door.  
         [0013]     In another embodiment of the present invention, a method is provided for forming holes in a first and second door. The method includes the steps of providing an angular frame having at least a first opening and a second opening defined in the frame, the frame including a plurality of spacing tabs mountable thereto; positioning the frame on an edge of the first door; forming openings in the first door guided by the first and second openings; and removing the frame from the first door. The method further includes the steps of mounting the spacing tabs to the frame; positioning the frame on an edge of the second door; and forming openings in the second door guided by the first and second openings.  
         [0014]     In an embodiment of the present invention, an apparatus is provided for drilling holes in the door for the mounting of a lockset. The apparatus comprises an angular frame for positioning along the edge of the door; a first cylindrical opening defined in the frame having a first axis and a second cylindrical opening defined in the frame having a second axis. The first and second axes intersect at approximately 90 degrees to each other. The apparatus further comprises at least one holesaw blade sized to fit within at least one of the openings and at least one spacing tab mountable to the frame for spacing the frame a predefined distance from the door.  
         [0015]     In another embodiment of the present invention, a method is provided for mounting a lockset on a door. The method includes the steps of providing a frame member having an L-shaped cross section; attaching the frame member to the door by having at least one first fastener through the frame member into the edge of the door; forming an opening for the mounting of the lockset using the frame member as a guide; removing the at least one first fastener and the frame from the door; and mounting the lockset in the opening.  
         [0016]     Other objects and advantages will be apparent from the following description of the invention, and the various features of that invention will be particularly pointed out in conjunction with the preferred embodiments. As realized, the invention is capable of other and different embodiments, and its details are capable of modification in various respect. Accordingly, the drawings and description are to be regarded as illustrative in nature and not as restrictive. 
     
    
     BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS  
       [0017]     The present embodiments of the invention are illustrated in the accompanying drawings wherein:  
         [0018]      FIG. 1  is a perspective view of a first embodiment of the lockset drilling guide in accordance with the present invention;  
         [0019]      FIG. 2  is a front elevational view of  FIG. 1 ;  
         [0020]      FIG. 3  is a top elevational view of  FIG. 1 ;  
         [0021]      FIG. 4  is a left-side elevational view of  FIG. 1 ;  
         [0022]      FIG. 5  is a perspective view of the lockset drilling guide of  FIG. 1  showing the rear portion thereof;  
         [0023]      FIG. 6  is a perspective view similar to that of  FIG. 5 , showing the adjustment tabs positioned and installed on the frame of the preferred embodiment; and  
         [0024]      FIG. 7  is a perspective view of the embodiment shown in  FIG. 1  installed on the edge of a door and showing various aspects of the lockset installation process;  
         [0025]      FIG. 8  is a top elevational view similar to that of  FIG. 3  showing the installation of the drilling guide on a standard, non-beveled door;  
         [0026]      FIG. 9  is an elevational view similar to that of  FIGS. 3 and 8  showing the installation of the drilling guide on a beveled door; and  
         [0027]      FIG. 10  is a top elevational view similar to  FIGS. 3, 8  and  9  showing the drilling guide installed on a door of reduced thickness. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0028]     A preferred embodiment of the invention is shown as a drilling guide  10  having a frame  12  as shown in the various views of  FIGS. 1-5 . The frame  12  is generally L-shaped in that the frame  12  includes a first flange  14  and a second flange  16  positioned relative to each other at a 90° angle. The first flange  14  preferably defines a generally flat, planar rear face  15  and a second flange  16  preferably defines a generally flat rear face  17 . A pair of upstanding, elongated spacing ridges  50  are provided along the rear face  17  of the second flange  16  to account for positioning along beveled door edges. The first flange  14  preferably defines a first circular opening  18  surrounded by an annular lip  20  that is configured as an upstanding right-cylindrical section. The annular lip  20  defines a right cylindrical wall  22  on the interior of the opening. It is preferred that the annular lip  20  upstands in a direction opposite that of the rear face  15  so that the rear face  15  remains generally flat. Preferably, the right cylindrical wall  22  defines a first central axis  24  that is generally perpendicular to the plane of the rear face  15  of the first flange  14 , as best seen in  FIG. 3 .  
         [0029]     The second flange  16  preferably defines a second opening  26  surrounded by an annular lip  28 . The annular lip  28  preferably upstands in an opposite direction from the rear face  17  of the second flange  16 , and, like the annular lip  20 , extends in a right-cylindrical section from the flange  16 . The annular lip  28  preferably defines a right cylindrical wall  32  on the interior of the second opening  26 . The right cylindrical wall  32  preferably defines a second central axis  34  that extends perpendicularly to the rear face  17  of the second flange  16  as shown best in  FIG. 3 . Thus, as shown in  FIG. 3 , the axes  24  and  34  of the first opening  18  and the second opening  16 , respectively, intersect at a 90° angle. The second flange  16  also preferably defines a pair of thorough-going mounting openings  40  that are positioned to surround the second opening  26 . Preferably, the centers of the mounting openings  40  are aligned with the center  44  of the second opening  26  as shown in  FIG. 4 . Preferably, the mounting openings  40  are positioned relative to the second opening  26  on the flange  16  to correspond to similar latch plate mounting openings on standard latch plates.  
         [0030]     Preferably, the right cylindrical wall  22  defining the first opening  18  is 2⅛ inches in diameter, and the right cylindrical wall  32  of the second opening  26  is 1 inch in diameter. In one embodiment, these measurements allow the right cylindrical wall  22  of the first opening  18  to closely surround and guide a standard holesaw having a 2⅛ inch diameter within the opening  18  so that the saw remains generally perpendicular to the rear face  15  during the drilling process. Similarly, the right cylindrical wall  32  of the opening  26  closely surrounds and is able to guide a smaller standard-sized holesaw for drilling a hole of 1 inch in diameter, thus keeping the holesaw perpendicular to the rear face  17  during the drilling process.  
         [0031]      FIG. 7  shows the forward edge of a door  200  that is being prepared for drilling.  FIG. 7  also illustrates the holesaws  100  and  102  adjacent the openings  18  and  26 , respectively, on the drilling guide  10  positioned on an undrilled door  200 . The door  200  preferably includes a door face  202  and a door edge  204 . As shown in the drawing, the drilling guide  10  may be mounted to the door  200  so that in the rear face  15  of the first flange  14  is positioned flush to the door face  202  and the spacing ridges  50  on the rear face  17  of the second flange  16  are positioned against the door edge  204 . This is shown in  FIG. 8 . The drilling guide  10  may be mounted to the door edge  204  using a pair of screws  42  inserted through the mounting openings  40  in the second flange  16 . Preferably, in the preferred embodiment, the screws  42  may be the same screws that are provided with a conventional lockset. Conveniently, once the drilling process is completed and the drilling guide  10  is removed from the door  200 , the screws  42  may be reused to attach the latch plate to the door edge  204 . The area surrounding the newly drilled opening will of course require a section properly mortised to fit the latch plate (not shown).  
         [0032]     When the drilling guide  10  is mounted with the frame  12  against a conventional-edge door  200 , the spacing ridges  50  are positioned against a flat door edge  204 . The proper positioning of the rear face  15  of the first flange  14  against the door face  202  allows the plane of the rear face to be properly aligned perpendicularly to the door edge  204 , and the center line  44  of the opening  26  aligned with the center line of door edge  204 . This is shown in  FIGS. 7 and 8 . when the drilling guide  10  is properly positioned on the door  200 , wherein the door is of a non-beveled edge configuration, the spacing ridges  50  are positioned on the edge  204  of the door as shown in  FIG. 8 . In the event that the door includes a beveled edge  304  as shown in  FIG. 9 , the spacing ridges  50  properly provide stability to the second flange  16  and engage the beveled edge  304  of the door  300 .  
         [0033]     Because the most often-used interior door sizes have thicknesses of 1⅜ inches and 1¾ inches, the drilling guide of the present invention may be adjusted for use on doors having at least these two thicknesses. In the preferred embodiment, the rear face  15  of the first flange  14  is placed flush against the face  202  of the door  200  for a 1¾ inch thick standard door as shown in  FIG. 8 . On thinner 1⅜ inch doors, it is desirable to adjust the guide so that the center line  44  of the second opening  26  on the flange  16  is still properly positioned along the center line of the edge of the thinner door. In order to accommodate this adjustment, a plurality of removable spacing tabs  60  are provided in the preferred embodiment. Preferably, the spacing tabs  60  are defined with generally parallel opposed surfaces  62  and  64 . The surface  62  of each tab  60  preferably includes an upstanding peg  66  that is sized to removably engage a corresponding opening  68  on the rear face  15  of the first flange  14 . Preferably, each of the spacing tabs  60  is flexibly attached by an integral, flexible strap  70  to the frame  12 . In the preferred embodiment, the three spacing tabs  60  are provided around the periphery of the first flange  14 . The straps  70  may be integrally molded of the same plastic or may include molded-in or co-molded elastomeric rubber to provide more flexibility.  
         [0034]     In use, when it desired to use the drilling guide  10  on a door of reduced standard thickness, the tabs  60  may be inserted into each corresponding opening  68  in the rear face  15  as shown in  FIG. 6 . The thickness of the tab  60 , in particular the distance between the opposed surfaces  62  and  64 , raises the first flange  14  slightly above the face of the door on which it is installed. Thus, the drilling guide  10  contacts the face of the reduced-thickness door only via the surfaces  64  of the tabs  60  in this configuration. This is shown in the top view of  FIG. 10 , which illustrates the mounted guide  10  on a thinner door  400 .  
         [0035]     When it is desired to re-use the drilling guide  10  on a door of increased standard thickness such as the door  200  shown in  FIG. 8 , the tabs  60  may be removed from the openings  68  and used as described above. Note that in  FIG. 8 , the spacing tabs  60  are allowed to flex away from the face  202  of the door  200  when the guide  10  is mounted thereto. Thus, the drilling guide  10  may be quickly reconfigured for use on various standard-sized doors.  
         [0036]     It should be noted that further adjustment options may be implemented in the preferred embodiment to allow use of the drilling guide  10  on doors of a variety of thicknesses. For example, a plurality of tabs of differing thicknesses may be provided for use on doors having a variety of thicknesses. Furthermore, the first opening  18  and the second opening  26  may be modified to receive properly sized holesaws, and the collars may also include an upstanding annulet or flange that varies the spacing between the rear  15  and the face of the door. Other alternative structures may of course be provided within the scope of the invention.  
         [0037]     The drilling guide  10  may then be adjusted for use on a door having less thickness than the previous door  200 , such as door  400  of  FIG. 10 . To adjust the drilling guide  10 , the user inserts the pegs  66  of the three spacing tabs  60  into the corresponding three openings  68  on the rear face  17  of the second flange  16 . The drilling guide  10  is then mounted on the door as shown in  FIG. 10 , and the same procedures are followed for drilling the holes in the door as described above in conjunction with  FIG. 7 .  
         [0038]     The frame  12  is preferably an integral, one-piece design molded from a rigid and durable plastic material. Exemplary plastic materials include ABS plastic, Lexan® or hard rubber materials. Also, the frame may be constructed from machined or molded metal, such as aluminum. In addition, the tabs  60  may be formed from rubber or similar flexible material and the tabs  60  may be mated to the frame  12  when the frame  12  is constructed from metal. It is intended that various framing artifacts, such as the bulkheads  13 , may vary in position to provide proper support to the frame  12  depending on the particular material being used. In the alternative, such artifacts and bulkheads  13  may be eliminated completely as long as support to the shape of the frame  12  is adequately maintained and depending on the material from which it is constructed.  
         [0039]     Of course, it should be understood that a wide range of changes and modifications could be made to the preferred embodiments described above. In particular, some of the specific measurements noted herein may be changed without departing from the invention. Thus, it is intended that the foregoing detailed description be regarded as illustrative rather than limiting. The scope of the invention is defined by the appended claims, and all devise that come within the meaning of the claims, either literally or by equivalence, are intended to be embraced therein.