Abstract:
A hand tool is used to automatically and precisely define a starting hole that will accommodate an element such as a self-tapping screw, a drill bit, or the like. The hand tool has a leading section that automatically orients and locates a punch rod that will be actuated by means of a trigger mechanism to define the starting hole.

Description:
BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to the general art of hand tools, and to the particular field of hand tools relating to elements which are driven into a substrate. 
   2. Discussion of Related Art 
   Hardware, such as hinges, templates, plates and the like are often mounted on a substrate such as a wall, door, door jamb, window jamb, window blind mounting hardware, cabinet mounting hardware, or the like. The hardware is often mounted using self-tapping screws or like elements. Some such hardware is mounted after a hole has been drilled in a desired location using a drill bit. Often, the hardware is located in difficult-to-reach locations. 
   Mounting such hardware often requires driving the mounting elements or a drill bit into the substrate using either a hand-powered tool, such as a screwdriver, or a power tool. Often, it requires two hands to drive the mounting element or drill bit into the substrate. One hand must be used to hold the element in place while the other hand is used to provide the power and/or force to actually drive the element into the substrate. This can be awkward, especially if the hardware is located in a difficult-to-reach location. 
   Therefore, there is a need for an appliance that can be used to facilitate the process of mounting hardware. 
   One problem with effecting such hardware mounting is associated with the driven element moving away from the desired target area just as force is applied to drive the element into the substrate. This problem can cause hardware to be mounted away from the desired location, or in some instances, actually prevent the hardware from being properly mounted. Skilled craftsmen have learned how to compensate for this problem, but unskilled individuals may have considerable difficulty and experience considerable frustration, due to this problem. Even skilled craftsmen sometimes have difficulty with this problem. 
   One way of dealing with this problem is to drive a nail or a punch into the substrate at the desired location by using a hammer or other such instrument. This method defines a starter hole or leading hole for the element, but requires two hands which may be difficult or cumbersome in many situations. Even then, the initial leading hole must be properly positioned with respect to the element-accommodating bore in the hardware. Thus, even if it is somewhat convenient to drive a punch into a substrate using a hammer to define the starting location for a hardware-mounting element, the exact location of that leading hole within the mounting element-accommodating bore of the hardware may have to be estimated. A skilled craftsman may be adept at this, but unskilled individuals may have difficulty. 
   Therefore, there is a need for a hand tool which can easily define a starter location for hardware-mounting elements and which will automatically properly locate that starter location. 
   Similar problems occur when a hole is to be drilled into a substrate. A drill bit may “walk” away from the desired location as the drill is activated thereby locating the drilled hole in an undesired location. This “walking” problem is generally accounted for by using a starter location as discussed above, but the problems associated with defining such a starter location for a drill bit are similar to those discussed above. Thus, it is to be understood that when reference is made to a mounting element, a drill bit will be included in such a term. 
   As there are many different types of hardware, any tool that is to be used to mount such hardware should be as versatile as possible. This will allow a user to easily apply the tool to a variety of jobs without requiring special adapter elements or without requiring the user to adapt special procedures. 
   Therefore, there is a need for a versatile hand tool which is used to define a starter location for hardware-mounting elements. 
   PRINCIPAL OBJECTS OF THE INVENTION 
   It is a main object of the present invention to provide a hand tool that can be used to facilitate the process of mounting hardware. 
   It is another object of the present invention to provide a hand tool which can easily define a starter location for hardware-mounting elements and which will automatically properly locate that starter location. 
   It is another object of the present invention to provide a versatile hand tool which is used to define a starter location for hardware-mounting elements. 
   SUMMARY OF THE INVENTION 
   These, and other, objects are achieved by a hand tool or appliance for defining a starting location for elements which are to be driven into a substrate. The hand tool comprises a housing having a nose section which includes a conical sidewall; a leading section on the nose section of the housing, the leading section having a conical sidewall that is oriented at an oblique angle to the conical sidewall of the nose section of the housing; a punch mechanism movably mounted in the housing to move between a cocked position and a released position; a biasing element on the punch mechanism to bias the punch mechanism toward the released position; a trigger mechanism mounted on the housing and having a sear element movably mounted on the housing to move between a punch mechanism-releasing position and a punch mechanism-cocking position with the punch mechanism being held against the bias of the biasing element when the trigger mechanism is in the punch mechanism-cocking position. 
   The hand tool or appliance embodying the present invention can be operated by one hand and, due to the double conical or beveled shape on the nose end of the hand tool, will automatically orient itself to define the starter or leader hole in the exact center of a mounting element-accommodating bore on hardware elements, such as hinges or the like. The shape of the leading nose end of the hand tool will have, in one form of the invention, the same degree of angle as the screw hole in a butt hinge that accommodates the angle of a screw head. This will make it easy for a user, even an unskilled user, to accurately define a starter or leader hole for a mounting element, such as a self-tapping screw or the like. The mounting element will then precisely position the hardware in the exact location and position desired. The leading hole will be accurately located so the mounted hardware will not be moved out of a desired position when a mounting element is inserted into the substrate through the mounting element-accommodating holes in the hardware. This will be the case even if the hardware is to be placed in a difficult-to-reach location. 

   
     BRIEF DESCRIPTION OF THE DRAWING FIGURES 
       FIG. 1  is a perspective view of a hand tool embodying the present invention in a released configuration. 
       FIG. 2  is a top plan view of the hand tool embodying the present invention in a use position. 
       FIG. 3  is an enlarged view taken along line  3 — 3  of  FIG. 1  showing the hand tool of the present invention in a cocked configuration in solid lines, as well as in a released configuration in phantom lines. 
       FIG. 4  is an end elevational view of the hand tool embodying the present invention. 
       FIG. 5  shows a further enlarged view of a single notch of a plurality of notches used in controlling movement of a punch mechanism of the hand tool embodying the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
   Other objects, features and advantages of the invention will become apparent from a consideration of the following detailed description and the accompanying drawings. 
   Referring to the figures, it can be understood that the present invention is embodied in an appliance or hand tool  10  for defining a starting location for elements which are to be driven into a substrate. Appliance  10  comprises a housing  12  having a handle section  14  which includes a first end  16 , a second end  18 , a first endwall  20 , a second endwall  22 , a length dimension  24  extending between the first endwall  20  and the second endwall  22 , and a height dimension  26  extending between the first end  16  and the second end  18 . The handle  14  is manufactured of plastics-type material to be easily, securely and comfortably grasped. 
   A main section  30  includes a first end  32  located near second end  18  of the handle section  14  and near second endwall  22  of the handle section  14 , a second end  34 , a sidewall  36  connecting the first end  32  of the main section  30  to the second end  34  of the main section  30  and a longitudinal axis  38  which extends between the first end  32  of the main section  30  and the second end  34  of the main section  30 . The sidewall  36  of the main section  30  is connected to the second end  18  of the handle section  14 . The main section  30  can also be manufactured of plastics-type materials. 
   An interior chamber  40  is defined in the main section  30  from adjacent to the first end  32  of the main section  30  to adjacent to the second end  34  of the main section  30 . The interior chamber  40  includes a first end  42  located adjacent to first end  32  of the main section  30  and a distal end  44  located near second end  34  of the main section  30  of the housing  12 . The distal end  44  of the interior chamber  40  is conical in shape and tapers toward the second end  34  of the main section  30  and has a base end  46  located adjacent to the second end  34  of the main section  30  of the housing  12  and an apex end  48  spaced apart from the base end  46  of the distal end  44  of the interior chamber  40  in the direction of the longitudinal axis  38  of the main section  30  of the housing  12 . 
   A first cutout portion  50  is defined through the sidewall  36  of the main section  30  of the housing  12  adjacent to first endwall  20  of the handle section  14  and adjacent to second end  18  of the handle section  14  of the housing  12 . The first cutout portion  50  intersects the interior chamber  40  of the main section  30  of the housing  12 . 
   A second cutout portion  52  is defined in the handle section  14  of the housing  12  through first endwall  20  of the handle section  14  of the housing  12  and adjacent to second end  18  of the handle section  14  of the housing  12 . The second cutout portion  52  intersects the first cutout portion  50 . 
   A nose section  60  is on second end  34  of the main section  30  of the housing  12  and includes a proximal end  62  on the second end  34  of the main section  30  of the housing  12  and a distal end  64  spaced apart from the second end  34  of the main section  30  of the housing  12  in the direction of the longitudinal axis  38  of the main section  30  of the housing  12 . A conically shaped sidewall  66  has a base  68  at the proximal end  62  of the nose section  60  and an apex portion  70  at the distal end  64  of the nose section  60 . Sidewall  66  of the nose section  60  is oriented at a first oblique angle  72  to sidewall  36  of the main section  30  of the housing  12 . 
   A conically shaped leading section  80  is located on apex portion  70  of the nose section  60 . Leading section  80  is used to automatically center the hand tool in a mounting element-accommodating bore of an element of hardware. As will be understood from the teaching of this disclosure, the leading section  80  will engage the hardware adjacent to the bore through that hardware as soon as the hand tool is applied to the hardware. The leading section  80  is conical, but is arcuate and thus will move into a bore evenly thereby automatically centering the hand tool with respect to the bore, no matter what size the bore is. Leading section  80  includes a base section  82  on the apex portion  70  of the sidewall  66  of the nose section  60  and an apex section  84  spaced apart from the base section  82  of the leading section  80  in the direction of the longitudinal axis  38  of the main section  30  of the housing  12 . Leading section  80  has a conical sidewall  86  which is also arcuate and which connects the base section  82  of the leading section  80  to the apex section  84  of the leading section  80 . Sidewall  86  of the leading section  80  is oriented at a second oblique angle  88  to the sidewall  66  of the nose section  60  of the main section  30  of the housing  12 . 
   A first cylindrical bore  90  is defined in the main section  30  of the housing  12  and extends from the apex end  84  of the leading section  80  of the main section  30 . Bore  90  extends through the nose section  60  of the main section  30  of the housing  12  and intersects the interior chamber  40  of the main section  30  of the housing  12 . 
   A second bore  92  extends through the first end  32  of the main section  30  of the housing  12  in the direction of the longitudinal axis  38  of the main section  30  of the housing  12 . Second cylindrical bore  92  intersects the interior chamber  40  and is axially aligned with the first cylindrical bore  90  and is spaced apart from the first cylindrical bore  90 . 
   A punch mechanism  100  is located in the interior chamber  40  of the main section  30  of the housing  12  and includes a main body  102  which includes a first end  104 , a second end  106 , and a longitudinal axis  108  which extends between the first end  104  of the main body  102  of the punch mechanism  100  and the second end  106  of the main body  102  of the punch mechanism  100 . Longitudinal axis  108  extends in the direction of the longitudinal axis  38  of the main section  30  of the housing  12 . A sidewall  110  connects the first  104  end of the main body  102  of the punch mechanism  100  to the second end  106  of the main body  102  of the punch mechanism  100 . Sidewall  110  of the main body  102  of the punch mechanism  100  includes a transverse axis  112  which extends across the longitudinal axis  38  of the main section  30  of the housing  12  and which is transverse to the longitudinal axis  108  of the main body  102  of the punch mechanism  100 . Second end  106  of the main body  102  of the punch mechanism  100  has a conical shape which corresponds to the conical shape of the distal end  44  of the interior chamber  40  of the main section  30  of the housing  12  and has an apex end  114 . 
   A plurality of notches, such as notch  120 , are defined in the main body  102  of the punch mechanism  100 . The notches are spaced apart from each other along the direction of the longitudinal axis  108  of the main body  102  of the punch mechanism  100 . Each notch of the plurality of notches includes a rear end wall  122  which extends from the sidewall  110  of the main body  102  of the punch mechanism  100  in the direction of the transverse axis  112  of the main body  102  of the punch mechanism  100  and has a first end  124  in the sidewall  110  of the main body  102  of the punch mechanism  100  and a second end  126  located inside the main body  102  of the punch mechanism  100 . A sloping front wall  130  has a first end  132  in the sidewall  110  of the main body  102  of the punch mechanism  100 . First end  132  of the sloping front wall  130  is spaced apart from the first end  124  of the rear wall  122  of the same notch  120 . The sloping front wall  130  extends from the sidewall  110  of the main body  102  of the punch mechanism  100  and has a second end  134  at the second end  126  of the rear wall  122  of the same notch  120 . 
   A punch rod  150  is located in the first cylindrical bore  90  of the main section  30  of the housing  12 . Punch rod  150  includes a proximal end  152  attached to the apex end  114  of the second end  106  of the main body  102  of the punch mechanism  100  and a distal end  154  which is conical in shape and has an apex tip  156 . 
   A guide rod  160  extends from first end  104  of the main body  102  through first end  32  of the main section  30  of the housing  12 . Guide rod  160  includes a distal end  162  located outside of the interior chamber  40  of the main section  30  of the housing  12 . A knob  164  is located on the distal end  162  of the guide rod  160 . 
   A biasing element  170 , such as a spring, is located on the guide rod  160  and is located inside the interior chamber  40  of the main section  30  of the housing  12 . Biasing element  170  has one end  174  abutting first end  104  of the main body  102  of the punch mechanism  100  and a second end  176  abutting first end  42  of the interior chamber  40  of the main section  30  of the housing  12 . Biasing element  170  biases the main body  102  of the punch mechanism  100  toward second end  34  of the main section  30  of the housing  12 . 
   Main body  102  of the punch mechanism  100  and punch rod  150  of the punch mechanism  100  and guide rod  160  of the punch mechanism  100  are unitary with each other and are movable in the main section  30  of the housing  12  between a cocked position shown in solid lines in  FIG. 3  with apex tip  156  of the punch rod  150  positioned inside first cylindrical bore  90  of the main section  30  of the housing  12  and a released position shown in phantom lines in  FIG. 3  with the apex tip  156  of the punch rod  150  of the punch mechanism  100  positioned outside the first cylindrical bore  90  of the main section  30  of the housing  12 . Biasing element  170  biases the main body  102  of the punch mechanism  100  toward the released position. Biasing element  170  can include a spiral spring, such as that shown in FIG.  3 . 
   A trigger mechanism  180  is mounted on the housing  12  and controls the release of the punch mechanism  100  from the cocked position thereof to be moved to the released position thereof under the influence of biasing element  170 . Trigger mechanism  180  includes a trigger element pivot pin  182  mounted on the main section  30  of the housing  12  and located in the first cutout portion  50  of the main section  30  of the housing  12 . 
   A trigger element  184  is pivotably mounted on the trigger element pivot pin  182  and extends through the first cutout portion  50  of the main section  30  of the housing  12 . Trigger element  184  has a first end  186  located outside the interior chamber  40  of the main section  30  of the housing  12  and a second end  188  located inside the interior chamber  40  of the main section  30  of the housing  12 . 
   A trigger element biasing element  190  is mounted on the handle section  14  of the housing  12 . Element  190  has a first end  192  which contacts the handle section  14  of the housing  12  and a second end  194  which is connected to the trigger element  184  between the trigger element pivot pin  182  and the first end  186  of the trigger element  184 . The trigger element biasing element  190  can be a spring and bias the first end  186  of the trigger element  184  away from the handle section  14  of the housing  12 . 
   A sear element pivot pin  200  is mounted on the main section  30  of the housing  12 . A sear element  202  is pivotably mounted on the sear element pivot pin  200  and has one end  204  connected to the second end  188  of the trigger element  184  for movement therewith. A second end  206  of the sear element  202  is located to contact a rear end wall  122  of one notch  120  of the plurality of notches defined in the main body  102  of the punch mechanism  100 . 
   A sear element biasing element  210  can be a spring and is connected to the sear element  202  between the second end  206  of the sear element  202  and the sear element pivot pin  200 . The sear element biasing element  210  biases the second end  206  of the sear element  202  toward the first end  32  of the main section  30  of the housing  12  and away from the second end  188  of the trigger element  184 . 
   The trigger element  184  is movable between a cocked configuration in  FIG. 3  with the second end  206  of the sear element  202  contacting the rear wall  122  of an associated notch  120  of the plurality of notches defined in the main body  102  of the punch mechanism  100  and holding the main body  102  of the punch mechanism  100  in the cocked position against the bias of the biasing element  170  of the punch mechanism  100  and a released configuration with the second end  206  of the sear element  202  spaced apart from the rear wall  122  of the associated notch  120  of the plurality of notches against the bias of the sear element biasing element  210 . 
   In one form of the hand tool  10 , oblique angle  88  between the sidewall  86  of the leading section  80  of the housing  12  and the sidewall  66  of the nose section  60  of the main section  30  of the housing  12  is between 40° and 50°, with the 40° angle being preferred. The leading section  80  has a chamfer or beveled shape that is the same degree of angle as a screw hole in a butt hinge that accommodates the angle of a screw head. This permits accurate center alignment when the screw is installed so as not to move the hinge or mounting hardware out of line when the screw head is seated in the beveled hole of the hinge. 
   Operation of the hand tool  10  is evident from the foregoing, but will be briefly discussed in the interest of complete disclosure. As indicated in the Figures, the hand tool is placed in the cocked position by pulling knob  164  away from the main section  30  of the housing  12  from the phantom line position shown in  FIG. 3  to the solid line position shown in FIG.  3 . The desired depth of a starter hole can be set by selecting an appropriate one of the notches  120 . The trigger mechanism  180  then holds the punch rod  150  in the solid line position shown in FIG.  3 . The cocked hand tool  10  is then positioned so the leading section  80  is pressed into the mounting element-accommodating bore of an element of hardware, such as a hinge H, as indicated in FIG.  2 . The conical and arcuate shape of that leading section  80  automatically orients the hand tool  10  so the punch rod  150  is accurately centered with respect to the accommodating bore and the thickness of the hardware is accounted for by selecting an appropriate one of the notches  120 . The trigger mechanism  180  is operated to release the sear from engagement in a notch  120  and thus to release the main body  102  of the punch mechanism  100 , and biasing element  170  forces the punch rod  150  toward the released position shown in phantom lines in FIG.  3 . The apex tip  156  engages the substrate, such as wall W and defines a starter hole that will be used to accommodate a mounting element, such as a self-tapping screw or the like. The hand tool  10  is then moved out of the way, and the mounting element can be applied to the substrate using any suitable tool or method. As can be understood from the foregoing, hand tool  10  can be operated with only one hand and can be easily manipulated even in difficult-to-reach places. The outwardly sloping shape of leading section  80  will accommodate bores of various sizes thereby making the hand tool  10  quite versatile. 
   It is understood that while certain forms of the present invention have been illustrated and described herein, it is not to be limited to the specific forms or arrangements of parts described and shown.