Abstract:
A metal sheet punch device for metal sheets which includes a longitudinally extended frame having forward and rearward ends and alignment devices for aligning the frame on a metal sheet. At least two metal punch devices are mounted on the frame, each including a metal punch support structure movably mounted on the frame and a metal punch having a pointed lower end, the metal punch mounted on the underside of the metal punch support arm structure. A support structure drive device such as a coiled spring is operatively connected to the metal punch support structure to rapidly move the metal punch support structure between a retracted position and an extended position and a trigger device is operatively connected to the metal punch devices to trigger each of them to drive the metal punch into the metal sheet to form at least two securement screw indentations therein.

Description:
BACKGROUND OF THE INVENTION 
   1. Technical Field 
   The present invention relates to punch devices and, more particularly, to a metal sheet punch device having a longitudinally extended frame having forward and rearward ends, an alignment device mounted on the frame for aligning the frame on a metal roof, at least two metal punch devices mounted on the frame, each device including a metal punch support arm structure movably mounted on the frame, a generally pointed metal punch mounted on the underside of the metal punch support arm structure, and a support arm structure drive device mounted on the frame which is operatively connected to the metal punch support arm structure to move the metal punch support arm structure between a retracted position and an extended position, and a trigger device operatively connected to each of the metal punch devices to trigger the metal punch devices to punch securement screw indentations in the metal roof. 
   2. Description of the Prior Art 
   Metal sheeting for roofs, ceilings and walls are used on many different types of buildings, including both commercial and residential structures. Of these, the metal roof is the most common use of metal sheeting, and the standard metal roof would include a wooden or metal roof frame consisting of a plurality of spaced beams, usually referred to as “nailers” or “purling”, extending between and connecting the upper sections of the walls of the building. Mounted on this framework are a plurality of metal roof sections, which generally have widths of between three and four feet (3′ to 4′ with the usual width being approximately 38″) and have lengths of six feet up to forty feet (6′ to 40′) depending on the intended use of the sheet. The metal sheet sections also are usually “corrugated” to include alternating raised and lowered sections of the roof section for increased structural stability. Once the metal roof section is placed on the underlying roof framework, the metal roof section is affixed to the roof framework by a plurality of screws or other such fasteners which extend downwards through the metal roof section into the framework underneath the metal roof section. The next section of the metal roof is then partially overlapped with the metal roof section affixed to the roof frame, and the process is continued until the metal roof is erected. 
   While the preceding description of the erection of the metal roof sounds relatively simple, in practice the erection of a metal roof is anything but simple. In fact, two main problems occur with virtually every metal roof erection, the first being that once the metal roof section is placed on the roof frame, the position of each beam must be estimated beneath the metal roof section to permit proper connection of the metal roof section to the roof frame. Second, the positioning and insertion of each of the fastening screws through the metal roof section should be in an alignment pattern which not only secures the metal roof section to the roof frame, but also is aesthetically pleasing to enhance both the functionality and appearance of the metal roof once it is erected. There is therefore a need for a relatively simple and efficient device which will properly align and space the screws being used to secure the metal roof section to the roof frame. 
   In the prior art, alignment of the securement screw indentations was generally performed by formation of a chalk line on the metal roof section. Specifically, a roof installer would extend a chalk line from one end of the metal roof section being installed to the opposite end thereof with the chalk line aligned above the metal roof section with the roof support beam positioned underneath the metal roof section such that when the chalk line was “snapped,” the resulting chalk line would be aligned generally parallel with the underlying roof beam. The roof installer would then proceed along the chalk line marking at generally equal distances the locations for the series of securement screw indentations to be formed in the metal roof section. Once the locations of the securement screw indentations were determined along the chalk line, the roof installer would then proceed to form the indentations with a metal punch and hammer, forming each of the indentations one at a time along the chalk line, or alternatively may even use only a self-tapping screw to pierce the metal sheet. Finally, the roof installer would return to each of the securement screw indentations and insert the securement screw into the indentation to secure the metal roof section to the underlying roof support beam. Although years of practice may increase the speed with which the above-described method is performed, it is abundantly clear that this procedure is time-consuming and fraught with opportunities for error and therefore there is a need for an improved system and device by which a plurality of securement screw indentations may be formed in the metal roof section in an accurate and efficient manner. 
   There are some devices found in the prior art which, when used in connection with some types of formed sheet metal such as gutters and the like, will form a punch hole in the metal. These single-punch devices have been in existence and have been used with metal gutters, but the modifications necessary to permit use of these devices with metal sheets often would render the devices inoperable for their original intended purpose. Furthermore, although these devices, if modified, could conceivably provide alignment for a single screw to be placed through a metal roof section into the underlying frame, they still will not solve the problem of the alignment of multiple screws and the spacing thereof to enhance the functionality and appearance of the series of screws. There is therefore a need for a multiple punch device which will not only provide alignment of the screw holes with the underlying roof frame, but will also space the screws in their preferred securement spacing to ensure both improved functionality and improved aesthetic appearance. 
   There is therefore a need for an improved metal sheet punch device. 
   Another object of the present invention is to provide a metal sheet punch device which includes a longitudinally extended frame having alignment devices mounted thereon to properly align the metal frame on the metal roof and at least two metal punch devices mounted on the frame for forming at least two indentations in the metal roof into which fastening screws may be quickly and easily inserted. 
   Another object of the present invention is to provide a metal sheet punch device in which the metal punch devices include a metal punch support arm structure movably mounted on the frame, a generally pointed metal punch having a pointed lower end mounted on the underside of the metal punch support arm structure, and a support arm structure drive device such as a spring or pneumatic jack which is operatively connected to the metal punch support arm structure to move the metal punch support arm structure between a retracted position and an extended position to drive the metal punch into the metal roof section. 
   Another object of the present invention is to provide a metal sheet punch device which will quickly and easily form multiple securement screw indentations in a metal roof section, the indentations being properly spaced from one another and generally accurately aligned with the underlying roof beam to which the metal roof section is to be affixed. 
   Another object of the present invention is to provide a metal sheet punch device which can be quickly and easily used to form the securement screw indentations, yet which does not necessarily require connection to an external power source, thus preventing wire entanglements and the necessity for hose connections required by other devices found in the prior art. 
   Finally, an object of the present invention is to provide a metal sheet punch device which is relatively simple and economical in construction and is safe, efficient, and accurate in use. 
   SUMMARY OF THE INVENTION 
   The present invention provides a metal sheet punch device for metal roofs which includes a longitudinally extended frame having forward and rearward ends and alignment devices mounted on the frame adjacent the forward and rearward ends for aligning the frame on a metal roof. At least two metal punch devices are mounted on the frame, each of the metal punch devices including a metal punch support arm structure movably mounted on the frame, the metal punch support arm structure movable between a retracted position and an extended position relative to the frame, and a generally pointed metal punch having a pointed lower end, the generally conical metal punch mounted on the underside of the metal punch support arm structure. A support arm structure drive device such as a coiled spring or pneumatic jack is mounted on the frame and operatively connected to the metal punch support arm structure to rapidly move the metal punch support arm structure between the retracted position and the extended position. Finally, a trigger device is operatively connected to the metal punch devices, the trigger device operative to trigger each of the support arm structure drive devices operatively connected to each of the metal punch devices to drive the metal punch support arm structures from the retracted position to the extended position such that the metal punches engage the metal roof positioned there underneath to generally simultaneously form at least two spaced-apart indentations in the metal roof by impact of the metal punches with the metal roof, the indentations then being used for the insertion and alignment of securement screws to secure the metal roof section on the underlying roof support frame. 
   The metal sheet punch device as thus described is far superior to those devices found in the prior art. Specifically, the ability of the present device to perform simultaneous multiple punches which are accurately aligned with the underlying roof frame greatly decreases the amount of time needed to align and lay out the punched indentations required when using the methods of the prior art, such as chalk lining or the like. Furthermore, because the present invention, when outfitted with coiled springs, is independent of any power source, it is much easier and safer for a roof installer to use than many other electrical or pneumatic devices used in construction. Also, because of the forward and rearward alignment devices mounted on the longitudinally extended frame, it is difficult for a user of the present invention to incorrectly use and align the invention, thus greatly reducing the opportunity for mistakes and increasing the efficiency with which the metal roof is assembled. Finally, because the metal sheet punch device of the present invention is generally intuitive in use, it does not take a great deal of training to learn to use the present invention, meaning that virtually any worker from the most skilled to the least skilled may use the present invention to properly and quickly produce securement screw indentations in the metal roof sections. It is thus seen that the present invention provides a substantial improvement over those roof punch devices found in the prior art. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of the metal sheet punch device of the present invention being used on a metal roof; 
       FIG. 2  is a perspective view of the metal sheet punch device of the present invention; 
       FIG. 3  is a detailed side elevational view of the present invention during the “cocking” phase of use; 
       FIG. 4  is a detailed side elevational view of the present invention immediately prior to triggering of the metal punches; 
       FIG. 5  is a detailed exploded perspective view of one metal punch device found in the present invention; 
       FIG. 6  is a detailed side elevational view of one metal punch device of the present invention showing the operation of the punch device; 
       FIG. 7  is a detailed side elevational view of one metal punch device of the present invention showing the metal punch forming an indentation in the metal roof section; and 
       FIG. 8  is a detailed side elevational view of the rearward end of the longitudinally extended frame showing the trigger bar being raised to trigger the operation of the metal punch devices. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENT 
   The metal sheet punch device  10  of the present invention is shown best in  FIGS. 1–4  as including a longitudinally extended frame  12  having a forward end  14  and rearward end  16  and a plurality of metal punch devices  50   a ,  50   b ,  50   c , and  50   d  which are movably mounted on the frame  12 . In the preferred embodiment, the longitudinally extended frame  12  is constructed as including a pair of generally parallel frame plates  18   a  and  18   b  which are constructed of a durable material such as metal, aluminum or hardened plastic and would have a length of approximately 36 to 60 inches, a vertical height of approximately 1 to 6 inches, and would be spaced from one another approximately 1 to 6 inches, the frame plates  18   a  and  18   b  being supported apart from and connected to one another by a plurality of spacer rods  20 . It is further preferred that each of the elements of the present invention be constructed of rigid and durable materials, and therefore it is expected that the metal sheet punch device  10  will be constructed of metal such as steel or aluminum or a hardened plastic material, depending on the intended functionality of the element being constructed. 
   Mounted on and extending forwards from forward end  14  of frame  12  is forward alignment device  22  which, in the preferred embodiment, would include a pair of mounting arms  24   a  and  24   b  extending forwards from the frame  12  and an alignment plate mounting bar  26  which extends between and connects the forward ends of mounting arms  24   a  and  24   b , as shown best in  FIG. 2 . Mounting on and extending forwards from alignment plate mounting bar  26  is the alignment plate  28  which, in the preferred embodiment, would be a generally rectangular or trapezoidal plate extending generally horizontally from the alignment plate mounting board  28  and would further include a generally U-shaped screw engagement slot  30  formed in the forward end of alignment plate  28  and extending rearwards towards frame  12  as shown best in  FIG. 2 . The screw engagement slot  30  is designed to fit over and engage a securement screw  92  which has already been mounted on the metal roof section  90  as shown best in  FIG. 1 . As this securement screw  92  is already accurately aligned on the metal roof section  90  extending into the underlying roof frame beam  94 , engagement of the securement screw  92  by the screw engagement slot  30  results in a precise proper alignment of the forward end  14  of longitudinally extended frame  12  on the metal roof section  90 . 
   Mounted on rearward end  16  of longitudinally extended frame  12  is a rearward alignment structure  32  which, in the preferred embodiment, includes a pair of downwardly depending rear alignment bars  34   a  and  34   b  mounted on the outside of each of the frame plates  18   a  and  18   b  and extending downward below the base of the frame plates  18   a  and  18   b  approximately one to four inches. Due to the overall length of longitudinal frame  12 , when the metal sheet punch device  10  is placed on the metal roof section  90  with the screw engagement slot  30  engaging securement screw  92 , the rear alignment bars  34   a  and  34   b  are positioned outside of the edge of metal roof section  90  to depend downwards over the roof frame beam  94  on which the metal roof section  90  is to be mounted. Each of the rear alignment bars  34   a  and  34   b  are positioned on the opposite side of the roof frame beam  94  thus ensuring that the metal sheet punch device  10  is properly aligned on the metal roof section  90  such that the securement screw indentations formed by the metal sheet punch device  10  are aligned with the roof frame beam  94  on which the metal roof section  90  is positioned. The positioning of the metal sheet punch device  10  is thus correctly performed by merely aligning the forward alignment structure  22  with the securement screw  92  and the rearward alignment structure  32  with the roof frame beam  94 , an operation which can be performed quickly and easily with a maximum degree of accuracy each and every time the metal sheet punch device  10  of the present invention is used. 
   The metal sheet punch device  10  of the present invention also may include forward and rearward frame support legs  36   a ,  36   b ,  38   a  and  38   b  mounted on and extending downwards from frame  12  which assist with the positioning and support of the frame  12  when placed on the metal roof section  90 . The metal sheet punch device  10  of the present invention also may include a forward handle  40  and a carrying strap (not shown) to facilitate the lifting and placing of the metal sheet punch device  10  on the metal roof section  90 . 
   While the positioning of the metal sheet punch device  10  of the present invention in the proper orientation is important, it would be of little effect if the formation of the securement screw indentations still need to be performed by hand. Therefore, the metal sheet punch device  10  of the present invention includes a plurality of metal punch devices  50   a–d  each of which are designed to mechanically create a securement screw indentation in the same manner each and every time to ensure accurate spacing and accurate placement of the securement screw indentations. As each of the metal punch devices  50   a–d  are generally identical to one another and are triggered in substantially the same manner, the following description of metal punch device  50   a  should be understood to apply equally to metal punch devices  50   b ,  50   c  and  50   d.    
   Metal punch device  50   a  is shown best in  FIGS. 5 ,  6  and  7  as including a metal punch support arm structure  52  which includes left and right punch support bars  54   a  and  54   b , actuating arm  56  mounted on and extending forwards from punch support bars  54   a  and  54   b  and the metal punch  58  itself which is mounted on the punch support bars  54   a  and  54   b  and extends downwards therefrom. The punch support bars  54   a  and  54   b , actuating arm  56  and metal punch  58  are secured to one another by a plurality of bolts  60  and the assembled metal punch support arm structure  52  is pivotally mounted on the longitudinally extended frame  12  via pivot bolt  62  which extends through the rearward ends of punch support bars  54   a  and  54   b  and through the frame plates  18   a  and  18   b.    
   Mounted on and extending between the frame plates  18   a  and  18   b  rearward of the metal punch support arm structure  52  is a spring anchor  64  which would preferably consist of a plate  66  having a bolt  68  extending therethrough to secure the back end of the coiled spring  70  such that when metal punch support arm structure  52  is pivoted about pivot bolt  62 , the tension in coiled spring  70  attempts to drive the metal punch support arm structure  52  downwards, or as is shown in  FIG. 7 , rotate the metal punch support arm structure  52  in a counterclockwise direction about pivot bolt  62  thus driving metal punch  58  downwards to contact the metal roof section  90  over which the metal sheet punch device  10  is positioned. Of course, it should be noted that the coiled spring  70  may be replaced by any appropriate drive device, such as a pneumatic or hydraulic piston or ram which would be connected to the metal punch support arm structure  52  in the appropriate manner to drive the metal punch support arm structure  52  downwards to drive metal punch  58  into the metal roof section  90  to create the securement screw indentation  96  shown best in  FIG. 7 . Such substitution of alternate drive devices would be understood by those skilled in the art of pneumatic and hydraulic systems. 
   The trigger mechanism for the metal punch support arm structure  52  is shown best in  FIGS. 5 ,  6  and  7  as including a pair of downwardly and forwardly depending trigger bars  74   a  and  74   b  between which extends an actuating arm engagement bolt  76  which extends through the generally L-shaped slot  57  in actuating arm  56  as shown best in  FIGS. 6 and 7 . The upper ends of trigger bars  74   a  and  74   b  are connected to trigger actuating arm  78  which extends along the length of frame plates  18   a  and  18   b  as shown best in  FIG. 6 . The trigger actuating arm  78  is slidably mounted between frame plates  18   a  and  18   b  such that the trigger actuating arm  78  may be slid in a generally horizontal plane. The sliding or “cocking” of the trigger actuating arm  78  is performed by the rotation of trigger bar  80  which is rotatably mounted on the frame  12  as shown best in  FIGS. 3 and 4 . The metal punch device  50   a  would thus be triggered in the following manner. 
   As trigger bar  80  is rotated upwards, trigger actuating arm  78  is slid rearwards towards the rearward end  16  of longitudinally extended frame  12  thus producing the movement shown best in  FIGS. 6 and 8  of the drawings. The movement of the trigger actuating arm  78  moves trigger bars  74   a  and  74   b  rearwards permitting actuating arm bolt  76  housed within L-shaped slot  57  of actuating arm  56  to slide rearwards and fall into the lower section of the L-shaped slot  57  as shown in  FIG. 6 . As trigger bar  80  is returned to its position adjacent the frame  12 , trigger actuating arm  78  is slid forwards and, as best shown in  FIG. 7 , the trigger bars  74   a  and  74   b  are slid forward also with actuating arm bolt  76  being temporarily caught within the lowermost portion of L-shaped slot  57  of actuating arm  56 . This causes the metal punch support arm structure  52  to be pulled upwards and forwards in clockwise rotation about pivot bolt  62  (from the viewpoint of  FIG. 7 ) thus tensioning coiled spring  70 . As the sliding of trigger actuating arm  78  continues, the actuating arm bolt  76  eventually reaches a point within L-shaped slot  57  of actuating arm  56  where it no longer is frictionally retained within the lowermost portion of L-shaped slot  57  and the actuating bolt  76  slides forwards within L-shaped slot  57  releasing actuating arm  56  and thus metal punch support arm structure  52 . The tension built up in coiled spring  70  thus is released driving the metal punch  58  downwards to impact the metal roof section  90  to create the securement screw indentation  96  as shown best in  FIG. 7 . As each of the metal punch devices  50   a–d  are generally identical and are generally identically connected to the trigger actuating arm  78  and trigger bar  80 , each of the metal punch devices  50   a–d  are generally simultaneously triggered to create four identical securement screw indentations  96  which are spaced along the metal roof section  90  in the predetermined indentation locations. The metal sheet punch device  10  may then be moved to the next location, aligned and triggered to create the next set of securement screw indentations in the metal roof section  90 . It is thus seen how quickly and easily a number of indentations is formed in the metal roof by use of the present invention, thus greatly increasing the efficiency of the user of the present invention and reducing mistakes and risks associated with those devices and systems found in the prior art for performing the indentation forming task. 
   For facilitating carrying of the metal sheet punch device  10  of the present invention, a carrying strap  82  may be attached to one or more of the spacer rods  20  as shown in  FIGS. 1 and 2 . The carrying strap  82  is preferably constructed of nylon or another such durable material and is used in conjunction with the trigger bar  80  to lift and carry the metal sheet punch device  10  between use locations. 
   It is to be understood that numerous modifications, additions and substitutions may be made to the present invention which fall within the intended broad scope of the appended claims. For example, the size, shape and construction materials used in connection with the metal sheet punch device  10  of the present invention may be modified or changed so long as the intended functionality of the invention is maintained. Likewise, the precise nature of the support arm structure drive device may be modified or changed to incorporate not only a coiled spring but other types of drive devices such as pneumatic or hydraulic pistons, any of which would be understood by those skilled in the art of such systems. Furthermore, the precise nature of the triggering device and precise arrangement of the metal punch devices may be modified or changed so long as the intended functional features of creating a plurality of securement screw indentations in a metal roof section in a general simultaneous manner is preformed. Finally, although the present invention has been described for use in connection with corrugated metal roofs, it may be adapted for use in virtually any situation where a plurality of spaced indentations are to be formed to permit the insertion of fastening devices therein. 
   There has therefore been shown and described a metal sheet punch device  10  which accomplishes at least all of its intended objectives.