Abstract:
The present invention relates, in general, to a punch assembly and methods of using same and, more particularly, to a punch assembly that is capable of accurately and repeatedly measuring an intersecting point at which a hold or indentation can be put in a sheet of material such as, but not by way of limitation, a sheet of metal.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application relates to U.S. Provisional patent application, U.S. Ser. No. 60/407,876, filed Sep. 4, 2002, entitled PUNCH ASSEMBLY AND METHODS OF USING SAME. 

   BACKGROUND OF THE INVENTION 
   FIELD OF THE INVENTION 
   The present invention relates, in general, to a punch assembly and methods of using same and, more particularly, to a punch assembly that is capable of accurately and repeatedly measuring an intersecting point at which a hold or indentation can be put in a sheet of material such as, but not by way of limitation, a sheet of metal. 

   
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       FIG. 1  is a top perspective view of a punch assembly constructed in accordance with the present invention. 
       FIG. 2  is a top plan view of a piece of material for use with the punch assembly of FIG.  1 . 
       FIG. 3  is a top plan view of a measuring member of the punch assembly of FIG.  1 . 
       FIG. 4  is a bottom perspective view of the punch assembly of FIG.  1 . 
       FIG. 5  is a perspective view of another embodiment of the punch assembly of FIG.  1 . 
       FIG. 6  is a perspective view of a measuring member of the punch assembly of FIG.  5 . 
       FIG. 7  is a close-up perspective view of a retractable pin and a guide of the punch assembly of FIG.  5 . 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Before explaining at least one embodiment of the invention 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 the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments or of being practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for purpose of description and should not be regarded as limiting. 
   Referring now to  FIG. 1  shown therein is a punch assembly  10 , constructed in accordance with the present invention and a sheet of material  12  properly positioned in the punch assembly  10  for punching. The punch assembly  10  is for punching a hole through or making an indentation in the sheet of material  12  at an intersection  14  of a first distance  16  as measured from a first side  18  of the piece of material  12  and a second distance  20  as measured from a second side  22  of the piece of material  12 . 
   The punch assembly  10  has a first handle  24  and a second handle  26 . The first handle  24  has a proximal end  28  and a distal end  30 . The second handle  26  has a proximal end  32  and a distal end  34 . The distal end  34  of the second handle  26  has a receiver assembly  36  having a center  37 . The distal end  30  of the first handle  24  is in contact with a blade assembly  38 . The first handle  24  and the second handle  26  are pivotally connected such that the blade assembly  38  moves toward the receiver assembly  36  and into the receiver assembly  36  as the proximal end  28  of the first handle  24  is pivoted toward the proximal end  32  of the second handle  26 . Likewise, the blade assembly  38  moves out of the receiver assembly  36  and away from the receiver assembly  36  as the proximal end  32  of the second handle  26  is pivoted away from the proximal end  28  of the first handle  24 . One of ordinary skill in the art would, given the present specification and drawings, understand that the punch assembly  10  is not limited to the first handle  24  and the second handle  26  embodiment shown in FIG.  1 . Rather, the punch assembly  10  may include any mechanism or biasing means (such as the first handle  24  and the second handle  26 ) so long as the blade assembly  38  is capable of being merely punched through and/or into the sheet of material  12  and thereafter into or in contact with the receiver assembly  36 . 
   Referring now to  FIG. 2 , shown in more detail is the sheet of material  12  suitable for punching a hole in or making an indentation in with the punch assembly  10 . For example, but not by way of limitation, the sheet of material  12  may be a sheet of steel, iron, wood, laminate and may be, in an alternate embodiment, a three-dimensional object such as a tube, j-channel, etc. The sheet of material  12  is substantially planar in configuration in the embodiment shown in FIG.  2 . The sheet of material  12  has an outer periphery  40 . The outer periphery  40  of the sheet of material  12  is typically rectangular or square in configuration such that the outer periphery  40  (in addition to the first side  18 , and the second side  22 ) further includes a third side  46  opposite the first side  18  and a fourth side  48  opposite the second side  22 . Although the sheet of material  12  is shown and described as a sheet of material, those skilled in the art will readily recognize and understand that the punch assembly  10  can be utilized for punching holes or making indentations in other configurations of material (i.e. three-dimensional objects) such as a sheet of metal that is formed into the configuration of a U channel. 
   Referring now to  FIG. 3 , the punch assembly  10  further includes a measuring member  50  capable of measuring and laying out the first distance  16 , the second distance  20 , and a third distance  21 . The measuring member  50 , in one embodiment, is substantially planar and has a modified U shaped configuration although other shapes may be utilized as will be apparent to one of ordinary skill in the art. The measuring member  50  is slidably attached to and extends from the distal end  34  of the second handle  26  of the punch assembly  10 . The measuring member  50  has a first appendage  52 , a second appendage  54  and a third appendage  56 . The first appendage  52  has an outer periphery  58  that may, in one embodiment shown in  FIG. 3 , be substantially rectangular in configuration. The second appendage  54  has an outer periphery  60  that may also be substantially rectangular in configuration. The first appendage  52  and the second appendage  54  are spaced a distance  62  apart and substantially parallel to one another. The first appendage  52  has at least one first elongated slot  63 . A first fastening element  64  is disposed through the elongated slot  63  and engages the distal end  34  of the second handle  26  so as to substantially and slidably connect the measuring member  50  to the distal end  34  of the second handle  26 . The second appendage  54  may also have at least one second elongated slot  65 . A second fastening element  66  is disposed through the second elongated slot  65  and engages the distal end  34  of the second handle  26  so as to substantially and slidably connect the measuring member  50  to the distal end  34  of the second handle  26 . The first appendage  52  further has a first set of measuring indicia  68  thereon for measuring the first distance  16  from the first side  18  of the sheet of material  12  to the center  37  of the receiver assembly  36 . The second appendage  54  further has a third set of measuring indicia  67  thereon for also measuring the first distance  16  from the first side  18  of the sheet of material  12  to the center  37  of the receiver assembly  36 . Indeed, the first set of measuring indicia  68  and the third set of measuring indicia  67  are identical and allow a user to see the first distance  16  from the first side  18  of the sheet of material  12  to the center  37  of the receiver assembly  36  from any visual vantage point when looking at the punch assembly  10 . 
   The third appendage  56  of the measuring member  50  is typically disposed at a substantially right angle to the first appendage  52  and extends from the first appendage  52  to the second appendage  54 . The third appendage  56  has a second set of measuring indicia  70  thereon for measuring the second distance  20  from the second side  22  of the sheet of material  12  to the center  37  of the receiver assembly  36 . 
   A first side stop  72  is moveably connected to the third appendage  56  for aligning the second side  22  of the sheet of material  12  and positioning the center  37  of the receiver assembly  36  the second distance  20  and therefore to substantially place the center  37  of the receiver assembly  36  at the intersection  14 . In an alternate embodiment, second side stop  74  can also be moveably connected to the third appendage  56  for further assisting in aligning the sheet of material  12 . 
   The receiver assembly  36  is disposed below the blade assembly  38  for receiving the blade assembly  38 . The blade assembly  38  and the receiver assembly  36  are configured and coordinated such that the receiver assembly  36  matingly receives the blade assembly  38 . In one embodiment, the blade assembly  38  is of a substantially cylindrical configuration and the receiver assembly  36  is in a matingly similar configuration. 
   However, the blade assembly  38  can be interchangeably connected to the distal end  30  of first handle  24  and the receiver assembly  36  can be interchangeably connected to the distal end  34  of the second handle  26  such that the blade assembly  38  and the receiver assembly  36  can be exchanged for different shaped blades and receivers to provide different shaped holes or indentations so long as the blade assembly  38  and the receiver assembly  36  are matingly compatible with one another. 
   Typically, the measuring member  50  is constructed from a relatively thin sheet of metal, although those skilled in the art will readily recognize that the measuring member  50  can be constructed from plastic or any other material suitable for use as the measuring member  50 . The third appendage  56  attaches to and is perpendicular to both the first appendage  52  and the second appendage  54  and typically extends a first distance  75  past the first appendage  52  and a second distance  76  past the second appendage  54 . The configuration in which the third appendage  56  is attached to the first and second appendages  52 ,  54 , respectively, provides the measuring member  50  with a substantially U-shaped configuration. Referring now to  FIG. 4 , the first elongated slot  63  and the second elongated slot  65  extend through the first and second appendages  52 ,  54 , respectively, and allow the first fastening element  64  and the second fastening element  66  to be disposed through the first and second appendages  52 ,  54 , respectively, to thereby provide one means for selectively moveably securing the measuring member  50  to the distal end  34  of the second handle  26  of the punch assembly  10 . The first fastening element  64  and the second fastening element  66  may be, for example, but not by way of limitation, screws, nuts, bolts, pins, spring loaded pins or derivations and combinations thereof. 
   The first side stop  72  includes a securing element  80  which is capable of being reversibly tightened to thereby reversibly join the first side stop  72  to the third appendage  56  in a desired location. The first side stop  72  is selectively slidably mounted to the third appendage  56  such that the first side stop  72  remains substantially parallel and coplanar with a rear guide  84  as the first side stop  72  is slidably moved along the third appendage  56 . The first side stop  72  also has an inner edge  73  which may be aligned with the second set of measuring indicia  70  on the third appendage  56 . The first edge  86  of the first side stop  72  in combination with the second set of measuring indicia  70  visually provide an accurate and reproducible indication of the second distance  20  measured from the first edge  86  of the first side stop  72  to the center of the blade assembly  38  of the distal end  30  of the first handle  24  of the punch assembly  10 . 
   The first, third, and second sets of measuring indicia  67 ,  68 ,  70 , respectively, can be, by way of example, in inches and fractions of inches or centimeters and millimeters or any other known or fanciful unit of measurement. 
   In an open condition of the punch assembly  10  (not shown) the blade assembly  38  and the receiver assembly  36  are disposed a distance apart. In a closed condition of the punch assembly  10  (as shown in  FIG. 1 ) the blade assembly  38  is substantially matingly disposed into and/or within the receiver assembly  36 . In an alternate embodiment, the punch assembly  10  further includes a spring (not shown) sized, configured, shaped and disposed so as to bias the first handle  24  and the second handle  26  in the open position of the punch assembly  10  such that the blade assembly  38  and receiver assembly  36  are disposed in the open position of the punch assembly  10 . The punch assembly  10  may be constructed from metal although it can be constructed of any suitable strong reasonably rigid material such as a hard plastic, ceramic, laminate, composite or combinations of any of these materials. Furthermore, portions of the punch assembly  10  may be constructed of metal and other portions of the punch assembly  10  may be constructed from ceramic, plastic, etc. The punch assembly  10  can further include a force multiplier (not shown) so as to provide additional leverage and impart additional pressure between the blade assembly  38  and the receiver assembly  36  for ease of disposing the blade assembly  38  through the sheet of material  12  disposed between the blade assembly  38  and the receiver assembly  36 . Furthermore, the blade assembly  38  and the receiver assembly  36  can be removably connected to the first handle  24  and the second handle  26 , respectively, so as to provide an interchangeable feature to the punch assembly  10 . For example, although the blade assembly  38  is shown and described as substantially cylindrical in configuration and the receiver assembly  36  is shown as in a hollow cylindrical configuration sized and disposed so as to manually receive the blade assembly  38  into the receiver assembly  36 , the blade assembly  38  may also be substantially square in configuration and the receiver assembly  36  sized and configured to receive the blade assembly  38  that is substantially square in configuration so as to punch out square holes instead of round holes in the sheet of material  12 . 
   In use, the first handle  24  and the second handle  26  are disposed so as to place the punch assembly  10  in an open configuration. The securing elements  80  are loosened so as to allow the measuring member  50  and the first and second side stops  72 ,  74 , respectively, of the third appendage  56  to freely move. The first side stop  74  is moved along the third appendage  56  until it aligns with the second set of measuring indicia  70  that represents the desired first distance  16  from the first side  18  of the sheet of material  12 . The securing element  80  of the first side stop  72  is tightened to secure the first side stop  72  of the third appendage  56  in the desired position. 
   The securing elements  80  are loosened such that the measuring member  50  can be moved into a position wherein the first set of measuring indicia and the third set of measuring indicia  64 ,  67 , respectively, on the first and second appendages  52 ,  54 , respectively, represent the second distance  20  from the second side  22  of the sheet of material  12  or, alternatively, the third side  46  of the sheet of material  12 . 
   The sheet of material  12  is thereafter disposed and positioned between the blade assembly  38  and the receiver assembly  36 . The securing elements  80  are tightened so as fix the measuring member  50  in the desired position and so as to also prevent the measuring member  50  from inadvertently moving out of the desired position. An inner edge  73  of the first side stop  72  aligns with the second set of measuring indica  70  on the third appendage  56  so as to conveniently display the distance from the inner edge  73  of the first side stop  72  to the center of the blade assembly  38 . The securing elements  80  are loosened so as to allow the measuring member  50  to move a desired predetermined distance from the blade assembly  38  and the receiver assembly  36 . A back edge  220  of the third appendage  56  is positioned in a desired distance from the rear guide  84 . 
   With the sheet of material  12  properly positioned between the blade assembly  38  and the receiver assembly  36  and properly aligned with the first set of measuring indicia  68  and the second set of measuring indicia  70  as the proximal end  28  of the first handle  24  is moved in a direction toward the proximal end  32  of the second handle  26 , the blade assembly  38  punches through the sheet of material  12  and thereby cuts a hole through, or makes an indentation in, the sheet of material  12  at the intersection  14  of the first distance  16  from the first side  18  of the sheet of material  12  and a second distance  20  from the second side  22  of the sheet of material  12 . 
   Referring now to  FIG. 5 , shown therein is a punch assembly  10 A similar to the punch assembly  10  for punching a hole in a sheet of material  12 A at the intersection  14 A of a first distance  16 A from a first side  18 A of the sheet of material  12 A and a second distance  20 A from a second side  22 A of the sheet of material  12 A. The punch assembly  10 A further includes a blade assembly  38 A and a receiver assembly  36 A similar to the blade assembly  38  and receiver assembly  36  in the punch assembly  10 . 
   The punch assembly  10 A further includes a platform  300  for support and stability as well as to allow for the application of greater force to the sheet of material  12 A that is to be punched. The punch assembly  10 A can be a manual punch or an automatic punch (an automatic punch is shown as punch assembly  10 A in  FIG. 5  although a manual punch, such as punch assembly  10  shown in  FIG. 1 , may also be used). The punch assembly  10 A includes a first guide  304  and a second guide  306 . The first guide  304  has a plurality of measuring indicia  308  disposed on an upper surface  310  of the first guide  304 . The first guide  304  is typically attached to the platform  300 . The first guide  304  also has at least one stop  312 . The at least one stop  312  is shown in greater detail in FIG.  7 . 
   The at least one stop  312  is moveably connected within the first guide  304  through a channel  314 . The at least one stop  312  is useful in aligning the sheet of material  12 A in the punch assembly  10 A. The at least one stop  312  may also include a spring loaded pin, a magnet or a threaded nut and bolt or any other fastening type element known in the art for reversibly fixing and ease of adjustment or the first stop. 
   The at least one stop  312  also includes a retractable pin  330  that extends upwardly from the at least one stop  312 . The retractable pin  330  can be moved from a closed configuration, wherein the retractable pin  330  is wholly contained within the at least one stop  312 , to a disposed configuration wherein the retractable pin  330  extends outwardly from the at least one stop  312  and engages the first guide  304 . When the retractable pin  330  engages the first guide  304 , the retractable pin  330  enters and extends through one of a plurality of holes  340  in the first guide  304  wherein the plurality of holes  340  generally are placed in conjunction with the plurality of measuring indicia  308  that are disposed on the upper surface  310  of the first guide  304 . In such manner, not only is the at least one stop  312  locked in place but the portion of the retractable pin  330  that extends above the upper surface  310  of the first guide  304  forms a stop upon which the sheet of material  12 A may be indexed against for determining the intersection  14 A. It is at the intersection  14 A that the blade assembly  38 A and receiver assembly  36 A, in operation, meet such that a hole or indentation are punched into the sheet of material  12 A by the punch assembly  10 A. 
   The second guide  306  (shown more particularly in  FIG. 6 ) includes a second plurality of measuring indicia  320  for measuring the second distance  20 A from the second side  22 A of the sheet of material  12 A. The second guide  306  can be threaded and attached to the first guide  304  such that as the second guide  306  screws in a first direction  322  the second guide  306  moves the second side  22 A of the sheet of material  12 A closer to the blade assembly  38 A and the receiver assembly  36 A, and when the second guide  306  is screwed in an opposite direction  324 , the second guide  306  moves the second side  22 A of the sheet of material  12 A farther from the blade assembly  38 A and the receiver assembly  36 A. 
   Thus, it should be apparent that there has been provided in accordance with the present a punch assembly and methods of using same that fully satisfies the objectives and advantages set forth above. Although the invention has been described in conjunction with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. Accordingly, it is intended to embrace all such alternatives, modifications, and variations that fall within the spirit and broad scope of the appended claims.