Patent Publication Number: US-10328557-B2

Title: Wall punch assembly and methods of use

Description:
This application claims the benefit of U.S. Provisional patent application No. 62/308,092 filed on Mar. 14, 2016, and U.S. Design patent application No. 29/584,846 filed on Nov. 17, 2016, both of which are incorporated herein in their entirety by this reference. 
    
    
     WALL PUNCH ASSEMBLY AND METHODS OF USE 
     The present invention relates to methods and apparatus that assist in hanging pictures or other things in a desired, level position on a wall or similar surface, and more particularly to a double nail insertion tool with sliding leveling assembly and sliding punch assembly, and methods use thereof. 
     BACKGROUND OF THE INVENTION 
     Generally, it is a difficult task for someone to position a picture, or other similar object, in a level placement on a wall when the object requires two or more mounting points. Holding the item, such as a picture, marking the spots to place the mounting studs, and inserting the studs often present problems, especially if performed by a single person. The task may require numerous attempts before a level placement is achieved, resulting in wasted time and multiple holes in the wall or other surface. 
     It would therefore be beneficial for homeowners, artists, home decorators, and others, to have a device that will aid them in quickly, safely and efficiently mounting objects in desired level manner without the need for another person to assist, nor the need for additional tools such as a tape measure, level, hammer, tape, etc. 
     SUMMARY OF THE INVENTION 
     The present invention makes it possible for one person to quickly, safely and efficiently hang and position objects on a wall or other similar surface requiring two or more support points by providing apparatus and methods for the insertion of two or more mounting studs (e.g., nails) into a wall or other similar surface, and placing the studs such that are level with each other. Embodiments of a basic unit of the present invention include at least two punch assemblies for inserting the mounting studs, the assemblies being movably provided on a pair of parallel stabilizing bars. It is to be appreciated that embodiments of the invention may include more than two punch assemblies. Each punch assembly resembles a stapler, and includes a large handle that is pivotally attached at one end to a base. The base of the pivoting end of each punch assembly is movably mounted to one of the stabilizing bars, and the another section of the base, which includes a unique nail insertion mechanism, is mounted to the other parallel stabilizing bar. 
     In preferred embodiments, one of the punch assemblies may be fixed to the proximal ends of the parallel stabilizing bars, with the distal ends of the bars attached to a hand grip and/or handle, thereby forming a frame. In these embodiments, the other punch assembly is being free to slide along the stabilizing bars to allow the user to choose an appropriate spacing between the mounting studs to be inserted. Other embodiments of the device may include a third slidably mounted punch assembly deployed between the first two, if desired. 
     A key element of each punch assembly is the large, pivotally attached handle. Embodiments of the handle allow for driving the studs into the wall by pivoting about the stabilizing bar and providing the necessary impact for inserting the stud when a force is applied to the free end of the punch assembly handle. A secondary benefit is that all nails or studs may be placed with the head protruding a desired (preferably identical) distance out from the wall, and at a desired angle for precision positioning. 
     Embodiments of the nail insertion mechanism, which is located opposite the pivoting end of punch assembly, include a sleeve for receiving a stud or nail, a magnet for holding the nail or stud in place, and a coil spring for maintaining the handle in striking position. Applying force to the punch assembly handle collapses the spring and drives a nail or stud into a wall. A key benefit is that the system is designed to insert a nail to an exact distance of the nail head to the wall and at a desired angle. 
     Embodiments of the dual nail insertion device of the present invention may include a strip with measuring indicia (e.g., a ruler) between the punch assemblies to allow for precise and repeatable placement of the nails. Such a measuring strip may be placed parallel to either of the stabilizing bars, preferably near or incorporated into the stabilizing bar adjacent to the nail insertion mechanism of each punch. 
     In embodiments of the invention, a sliding bubble level may be attached to the ruler for the purpose of providing properly aligned (i.e., level) nails. For more precise leveling, and to allow for the use of reference(s) to other objects on or near the wall, a laser pen may be attached to the frame, such as, for example, at one or both ends of the tool. 
     In embodiments of the invention, the pivoting handle of each punch may have openings to allow the user to view the measurements on the ruler to confirm placement of a nail before it is inserted. These openings may include magnified lenses to assist in such viewing. 
     In embodiments of the invention, an extension may be provided on one or more of the handles of the punch assemblies to provide additional torque when inserting a nail into a wall. In embodiments of the invention, the hand grip at one end of the frame may extend out from (i.e., perpendicular to) the wall or other surface to facilitate easy movement and adjustment of the device. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The various advantages of this invention may be more fully appreciated when considered in conjunction with accompanying drawings. 
         FIG. 1  is a top perspective view of an embodiment of the invention showing the supporting frame with optional ruler, fixed punch assembly, sliding punch assembly, magnetized nail tray, and bubble level assembly. 
         FIG. 2A  is another top perspective view of an embodiment of the invention. 
         FIG. 2B  is a top plan view of the embodiment of  FIG. 2A . 
         FIG. 3  is an exploded view and a constructed view of an embodiment of a punch assembly of the invention including a handle, base, and elements of an embodiment of a nail holding unit that includes button assembly, magnet, anvil, and coil spring. 
         FIG. 4  is a side view of an embodiment of the present invention. 
         FIG. 5  is an opposite side view of an embodiment of the present invention. 
         FIG. 6  is a side view of an embodiment of a punch assembly of the present invention. 
         FIG. 7  is an opposite side view of an embodiment of a punch assembly of the present invention. 
         FIG. 8  is a cross-sectional side view of a punch assembly of the present invention containing a nail in position for nail insertion and the placement of the nail to be inserted. 
         FIG. 9  is a bottom view of an embodiment of the present invention. 
         FIG. 10  is a top view of an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     Referring to the drawings wherein like reference characters designate like or corresponding parts throughout the several views, and referring particularly to  FIGS. 1-3 , it is seen that the illustrated embodiment includes a frame  10  having a first punch assembly  11  fixed at one end thereof, an end frame section that includes a handle  12  at the opposite end thereof, a connecting member  13  provided between the fixed punch assembly  11  and the end handle  12 , and a second connecting member  15  provided in parallel with connecting member  13  between punch assembly  11  and end handle  12 . In the illustrated embodiment, connecting member  13  is flat and connecting member  15  is a cylindrical rod, but other configurations may also be used for these connecting members. A second slidable punch assembly  16  is provided on frame  10  that is movable along member  13  and rod  15  between the fixed punch assembly  11  and end handle  12 . In the illustrated embodiment, the connecting member  13  is in the form of a ruler that allows measurement alignment, and which supports a sliding bubble level assembly  14 . 
     The fixed punch assembly  11  and the sliding punch assembly  16  provide for a sturdy frame and variable-position insertion of nails or studs, using their handles  21  for impact on the nails  20  to be inserted. The illustrated sliding bubble level assembly  14  is provided for proper leveling. An optional magnetic nail tray  17  may be provided on assembly  14  located on the flat portion of the frame  13 . An optional laser  18  may be provided for more precise leveling and, when needed, alignment with other references located at a distance on a wall. Apertures  19  may be provided in the handles  21  of the punch assemblies  11  and/or  16  in order to allow for viewing (which may include magnification) through the punch assemblies for more accurate placement of nails. These components may be integrated to provide the user all of the necessary elements for effective nail insertion in one complete package. 
       FIG. 3  shows views of an exemplary punch assembly including a handle  21  pivotally mounted to a base  29 , and a mechanism for holding nails in place prior to insertion. A key component is the mechanism that holds a nail in place prior to insertion into a wall. In the exemplary embodiment of  FIG. 3 , the illustrated mechanism includes a button assembly  23  having a bore  22  therein for tightly holding a nail  20 , a magnet  24  for holding a metallic nail  20  inside the button assembly  23 , an optional anvil to absorb impact, and a coil spring  26  that urges the assembly to an open position for loading a nail and placement on a wall. All of these components work together to provide for a solidly held nail prior to insertion. The base  29  of the sliding punch assembly  16  may include one or more spring mechanisms  27  that act against flat member  13  to hold the base  29  on member  13  at a desired location. A round roll pin  28  may be inserted into the punch assembly base  29  to allow the handle portion  21  to pivot about the punch assembly when the handle is impacted. Rubber pads  25  may also be provided underneath base  29  to prevent base  29  from damaging or scraping against the wall. 
       FIG. 8  shows a cross-section of an embodiment of a punch assembly, showing the elements in place in a ready-to-go position prior to inserting a nail  20 . Applying force to the handle  21  of the punch assembly provides the necessary impact to insert the nail. The button assembly  23 , with magnet  24 , bore  22 , spring  26  and base  29  form a system for holding the nail  20  in place prior to its insertion into a wall. The spring holds back the handle and the magnet holds the nail in place until impact. After impact, the spring pushes the handle back to its pre-impact position. 
     In alternative embodiments, an extension (not shown) may be provided on each of handles  21  of the punch assemblies  11  and  16 . These extensions provide a larger surface against which a user may exert force to drive a nail  20  into a wall. In some embodiments, these extensions may connect together so that the user may insert both nails by imparting a single force to both extensions. 
     In alternative embodiments, frame handle  12  may extend out from (i.e., perpendicular to) the wall or other surface to facilitate easy movement, adjustment and positioning of the device. 
     It is to be appreciated that in order to provide for clean, accurate and predictable placement and insertion of nails, the nails must be snugly secured to avoid any wobbling or side movement during the insertion process. Accordingly, embodiments of the invention include a narrow channel inside button assembly  32  for holding the nails. It is therefore to be appreciated that the nails used in most embodiments of the invention will have shafts and pointed ends, but will not have heads, since this would require a wider channel and would open the possibility of mis-directed nail insertions. In other embodiments, the nails may have heads, but are preferably elongated headless shafts (e.g., finishing nails) that fit snugly in the sleeves to provide more precise insertion. 
     Operation of a Preferred Embodiment 
     In order to use the illustrated embodiment of the invention, nails  20  are loaded into both punch assemblies  11  and  16 , and slidable punch assembly  16  is positioned along stabilizing bar  13  (using the measurements of the ruler) so that the two punch assemblies are spaced apart at a selected distance. The frame  10  is then placed against the wall, and moved until it is level according to the bubble level  14  on the ruler, and/or according to the optional laser  18 . The user then inserts nails by applying punching force to the handles  21  of each punch assembly, thereby driving a nail from each assembly into the wall. The frame is removed from the wall, and each assembly is then re-loaded with another nail for the next use. 
     It is to be appreciated that different versions of the invention may be made from different combinations of the various features described above. It is to be understood that other variations and modifications of the present invention may be made without departing from the scope thereof. It is also to be understood that the present invention is not to be limited by the specific embodiments disclosed herein, but only in accordance with the claims when read in light of the foregoing specification.