Patent Publication Number: US-2022212271-A1

Title: Auto-adjustable pocket hole jig docking station

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of U.S. Provisional Patent Application No. 63/114,143, filed 16 Nov. 2020. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to pocket hole jig tools, and more specifically to pocket hole jig tools that are adjustable. 
     BACKGROUND OF THE INVENTION 
     Pocket hole joinery is used extensively in woodworking as a quick and easy way to join two wood workpieces. A pocket hole is a pilot hole drilled at an angle in a first wood workpiece to align a screw for fastening to a second workpiece. A step drill creates a counterbored hole, or pocket, for the head of the pocket screw and a smaller diameter for body clearance. The counterbore or pocket of the pocket holes receive the pocket hole screw heads, hiding them in the internal, underside construction areas of woodworking projects. 
     It is important for the pocket hole to be drilled to the correct height in a workpiece. If the height is too small, the screw will stick through the surface of the joined part. If the height is too big, the joint will not be as strong as it should be. The correct pocket height will be different for different thickness of wood and different screw lengths. 
     Currently, various jigs have been provided for assisting in the drilling of pocket holes. However, precision and correctly measuring placement of the hole in a workpiece is important. Current jigs are useful in correctly forming holes in a workpiece, but they require extensive measurements during positioning of a workpiece or extensive trial and error to find the correct placement. These devices are often cumbersome and difficult to use. 
     It would be highly advantageous, therefore, to remedy this and other deficiencies inherent in the prior art. 
     Accordingly, it is an object of the present invention to provide new and improved pocket hole jig which is adjustable automatically. 
     It is another object of the present invention to provide new and improved pocket hole jig which can be used as a hand held stand-alone device or used in combination with a base. 
     SUMMARY OF THE INVENTION 
     Briefly to achieve the desired objects and advantages of the instant invention, provided is an auto-adjusting pocket hole jig docking station. The docking station includes a housing and an adjustment mechanism carried by the housing. The adjustment mechanism includes a first rack reciprocally movable between a raised position and a lowered position, relative the body, and a second rack reciprocally movable between a raised position and a lowered position, relative the body. A double pinion gear is rotatably carried by the housing. The double pinion gear includes a first gear in meshing engagement with the first rack and a second gear in meshing engagement with the second rack. The first gear and the second gear of the double pinion gear having a rotational ratio therebetween determining the relative movement of the first and second racks, wherein movement of one of the first rack and the second rack moves the other of the first rack and the second rack a distance proportional to the rotational ratio. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Specific objects and advantages of the instant invention will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment thereof taken in conjunction with the drawings, in which: 
         FIG. 1  is a perspective view of an auto-adjusting pocket hole jig docking station, in accordance with the present invention; 
         FIG. 2  is a perspective view of the auto-adjusting pocket hole jig docking station of  FIG. 1 , as it would appear being received by a guide block and base of a conventional pocket hole jig; 
         FIG. 3  is a perspective view of an auto-adjusting pocket hole jig docking station with a fixed guide block, in accordance with the present invention; 
         FIG. 4  is a perspective view of the auto-adjusting pocket hole jig docking station of  FIG. 3 , as it would appear being received by the base of a conventional pocket hole jig; 
         FIG. 5  is an exploded view of the auto-adjusting pocket hole jig docking station of  FIG. 4 , as it would appear being received by the base of a conventional pocket hole jig 
         FIG. 6  is a side view of the auto-adjusting pocket hole jig docking station of  FIG. 4  with the plunger gear rack in the lowered position; 
         FIG. 7  is a side view of the auto-adjusting pocket hole jig docking station of  FIG. 4  with the plunger gear rack in the raised position; 
         FIG. 8  is a perspective view of the auto-adjusting pocket hole jig docking station of  FIG. 4  with the plunger gear rack gauging a workpiece; 
         FIG. 9  is a perspective view of an auto-adjusting pocket hole jig docking station with accompanying removable drill guide pocket hole jig, according to the present invention; 
         FIG. 10  is a perspective view of the auto-adjusting pocket hole jig docking station as it would appear being received by a conventional pocket hole jig; 
         FIG. 11  is an exploded view of an auto-adjusting pocket hole jig docking station with accompanying removable drill guide pocket hole jig, according to the present invention; 
         FIG. 12  is a perspective view of the auto-adjusting pocket hole jig docking station with accompanying removable drill guide pocket hole jig, gauging a workpiece; 
         FIG. 13  is a perspective view of the auto-adjusting pocket hole jig docking station gauging a workpiece, as it would appear being received by a conventional pocket hole jig; 
         FIG. 14  is a side view of the auto-adjusting pocket hole jig docking station with accompanying removable drill guide pocket hole jig; 
         FIG. 15  is a side view of the auto-adjusting pocket hole jig docking station as it would appear being received by a conventional pocket hole jig; 
         FIG. 16  is a perspective view of the removable drill guide pocket hole jig positioned on a workpiece; 
         FIG. 17  is a perspective view of the auto-adjusting pocket hole jig docking station illustrating the drill bit stop collar positioning system according to the present invention; 
         FIG. 18  is a perspective view of a reversible channel element receivable by a guide block, according to the present invention; 
         FIG. 19  is a top view of the reversible channel block of  FIG. 18 ; 
         FIG. 20  is top view of a guide block receiving a reversible channel block; 
         FIG. 21  is a perspective view of a reversible channel block having a small channel with associated drill bit, and a perspective view of a reversible channel block having a large channel with associated drill bit; and 
         FIG. 22  is a perspective view of an auto-adjusting pocket hole jig docking station according to the present invention carried by a pocket hole jig base having a clamping mechanism and horizontal drill adjustment mechanism. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Turning now to the drawings in which like reference characters indicate corresponding elements throughout the several views, attention is first directed to  FIG. 1  which illustrates an auto-adjusting pocket hole jig docking station, generally designated  10 , in accordance with the present invention. Docking station  10  includes a housing  12  having a housing body  14 , a cover portion  15 , a top end  17  and a bottom end  18 . An adjustment mechanism  20  is reciprocally carried by housing  12  and includes a guide block gear rack  22  and a plunger gear rack  24 . Further details of adjustment mechanism  20  will be described in the following embodiment. An attachment fixture  30  is carried by an upper end of guide block gear rack  22 . Attachment fixture  30 , in this preferred embodiment includes a bracket  32  having an end  34  attached to the upper end of guide block gear rack  22  and an opposing end  36  carrying a set screw  38 . 
     With additional reference to  FIG. 2 , docking station  10  is illustrated being received by a conventional pocket hole jig base  40  and guide block  42 . Housing  12  is attached to the side of base  40  using fasteners such as screws  44  passing through apertures  45  formed therein and being received by base  40 . A top end of guide block  42  is engaged by bracket  32 . Tightening of set screw  38  fixedly attaches bracket  32  to guide block  42 , capturing guide block  42  between end  34  and end  36 . When installed, housing  12  of docking station  10  is removably fixedly attached to base  40  and bracket  32  is removably fixedly attached to guide block  42 . As will be described presently, this arrangement permits guide block gear rack  22  to reciprocally move vertically with a corresponding movement of guide block  42 , while housing  12  remains fixed an immovable with respect to base  40 . Thus, a docking station is taught which can be attached to an existing pocket hole jig guide block  42  and base  40 . 
     Referring now to  FIG. 3 , another embodiment of an auto-adjusting pocket hole jig docking station, generally designated  110 , is illustrated. Docking station  110  is substantially the same as docking station  10  with the difference being that a replacement guide block is provided integrally coupled to docking station  110 . Docking station  110  includes a housing  112  having a housing body  114 , a cover portion  115 , a top end  117  and a bottom end  118 . An adjustment mechanism  120  is reciprocally carried by housing  112  and includes a guide block gear rack  122  and a plunger gear rack  124 . Guide block gear rack  122  is integrally formed along a side of a replacement guide block  142  ( FIG. 5 ). 
     With additional reference to  FIG. 4 , docking station  110  is illustrated being received by a conventional pocket hole jig base  40 . Housing  112  is attached to the side of base  40  using fasteners such as screws  144  passing through apertures  145  formed therein and being received by base  140 . When installed, housing  112  of docking station  110  is removably fixedly attached to base  40  and guide block  142  is received by base  40 . Guide block  142  and integrally formed guide block gear rack  122  are reciprocally movable vertically with respect to base  40  while housing  112  remains fixed an immovable with respect to base  40 . Thus, a docking station is taught which can be attached to an existing pocket hole jig base  40 . 
     Turning now to  FIG. 5 , an exploded view of docking station  110  coupled to base  40  is illustrated. Adjustment mechanism  120  in the preferred embodiment includes a rack and pinion system carried by housing  12 . Double pinion gear  152  (circular gear), includes an inner gear and an outer gear having a desired rotational ratio therebetween. Double pinion gear  152  is rotatably carried within housing  112  in a void  154  defined by housing body  114 . Housing body  114  includes a vertical channel  156  extending from top end  117  to bottom end  118  adjacent forming a tangent to, and in communication with void  154 . Guide block gear rack  122  and plunger gear rack  124  (linear gears) extend through vertical channel  156  adjacent to and in meshing engagement with double pinion gear  152 . Guide block gear rack  122  engages the inner gear of double pinion gear  152  for reciprocal movement of guide block  142 , and plunger gear rack  124  engages the outer gear of double pinion gear  152  for reciprocal movement of plunger gear rack  124  between a raised position and a lowered position. Plunger gear rack  124  terminates at an upper end in a collar receiver  158 , terminates at a lower end with a contact foot  159 , and includes screw size indication indicia  160  carried therebetween. A window  165  is formed in cover portion  115  through which the screw size indication indicia  160  can be seen. 
     With additional reference to  FIGS. 6-8 ,  FIG. 6  illustrates plunger gear rack  124  in a lowered position, with contact foot  159  visible below bottom end  118  and positioned above a supporting surface.  FIG. 7  illustrates plunger gear rack  124  in a raised position, with contact foot  159  positioned within bottom end  118 . Movement of plunger gear rack  124  between the raised and lowered positions rotates double pinion gear  152  by rotating the outer gear with which it meshes. Rotation of the outer gear correspondingly rotates the inner gear with which guide block gear rack  122  meshes. Rotation of the inner gear moves guide block  142  upwardly or downwardly within pocket hole jig base  40  in a relative relation to movement of plunger gear rack  124  due to the ratio between the inner and outer gears of double pinion gear  152 . Referring specifically to  FIG. 8 , operation of auto-adjusting pocket hole jig docking station  110  is illustrated in use with a workpiece  170 . Workpiece  170  is positioned on the worksurface adjacent base  40  underlying contact foot  159  of plunger gear rack  124 . Plunger gear rack  124  is moved downwardly until contact foot  159  contacts the surface of workpiece  170 . The downward movement of plunger gear rack  124  results in the movement of guide block  142  to a position appropriate to the pocket forming process with regard to the thickness of that particular workpiece  170 . With plunger gear rack  124  positioned and secured, workpiece  170  can be removed and placed on base  40  for drilling. The position of plunger gear rack  124  auto-adjusts guide block  142  to the position required to form pocket holes in work piece  170 . 
     The movement of plunger gear rack  124  also adjusts the position of collar receiver  158  relative housing  112 . A drill bit  172  carried in a vertical slot formed in housing  112  has a base end  174  extending upwardly through collar receiver  158 . Collar receiver  158  carries a stop collar  176  therein through which base end  174  of drill bit  172  extends. As plunger gear rack  124  is moved upwardly or downwardly relative housing  112 , collar receiver  158  moves stop collar  176  upwardly or downwardly on drill bit  172 , positioning stop collar  176  appropriately for drilling pocket holes in workpiece  170  the required depth for the thickness of the workpiece used. Additionally, once the workpiece has been used to position plunger gear rack  124 , the screw size indication indicia  160  visible through window  165  indicates the screw size to be employed with the workpiece used. 
     Referring now to  FIGS. 9 and 10 , another embodiment of an auto-adjusting pocket hole jig docking station, generally designated  210 , is illustrated. Docking station  210  is intended to be a handheld calibration unit used on a conventional pocket hole jig unit, or used with a removable drill guide pocket hole jig  211  as will be described presently. Removable drill guide pocket hole jig  211  and auto-adjusting pocket hole jig docking station  210  are removably coupled by an attachment fixture. When auto-adjusting pocket hole jig docking station  210  is used with a conventional pocket hole jig  202  ( FIG. 10 ), drill guide pocket hole jig  211 , is removed from auto-adjusting pocket hole jig docking station  210  and auto-adjusting pocket hole jig docking station  210  is positioned on a conventional guide block  205  carried by conventional base  206 . 
     With additional reference to  FIG. 11 , auto-adjusting pocket hole jig docking station  210  includes a housing  212  having a housing body  214 , a cover portion  215 , a top end  217  a bottom end  218 , a back  213  and a front  216 . An adjustment mechanism  220  is reciprocally carried by housing  112  and includes a guide block gear rack  222  and a plunger gear rack  224 . Adjustment mechanism  220  in this preferred embodiment includes a rack and pinion system carried by housing  212 . Double pinion gear  252  (circular gear), includes an inner gear and an outer gear having a desired rotational ratio therebetween. Double pinion gear  252  is rotatably carried within housing  212  in a void  254  defined by housing body  214 . Housing body  214  includes a vertical channel  256  extending from top end  217  to proximate bottom end  218  forming a tangent to, and in communication with void  254 . Plunger gear rack  224  (linear gear) extend through vertical channel  256  adjacent to and in meshing engagement with an outer gear of double pinion gear  252  at a side thereof toward back  213  of housing  212 . Guide block gear rack  222  is positioned between housing body  214  and cover portion  215  and in meshing engagement with an inner gear of double pinion gear  252  at a side thereof toward front  216  of housing  212 . Guide block gear rack  222  has a depth stop end  230  that extends downwardly below bottom end  218  of housing  212 , and plunger gear rack  224  extends upwardly above top end  217  of housing  212 . Plunger gear rack  224  terminates at an upper end in a contact foot  259  with a collar receiver  258  formed therein. Plunger gear rack  224  also includes screw size indication element  260  carried below contact foot  259 . A window  265  is formed in cover portion  215  through which the screw size indication element  260  can be seen. 
     Still referring to  FIGS. 9 and 11 , drill guide pocket hole jig  211  includes a guide block  242  having a front surface  243 , a back surface  244 , a top end  245  and a bottom end  246 . Guide channels  247 , for receiving a drill bit therethrough, are formed in guide block  242  extending from the top end  245  to bottom end  246 . A slot  248  is formed in bottom end  246  extending toward top end  245  and slidably receiving a depth stop member  249 . Depth stop member  249  is movable between a retracted position and an extended position. Drill guide pocket hole jig  211  is removably coupled to housing  212  by an attachment fixture including coupling elements extending between housing  212  and guide block  242 , and between housing  212  and depth stop member  249 . In this preferred embodiment, the preferred coupling elements include magnets carried by housing  212  on guide block gear rack  222  and housing body  214 , and complemental magnets carried by guide block  241  and depth stop member  249 . 
     With additional reference to  FIG. 12 , plunger gear rack  224  is illustrated with a workpiece  270  captured between contact foot  259  and top end  217  of housing  212 . Movement of plunger gear rack  124  between a raised position and a lowered position to capture workpiece  270  rotates double pinion gear  252  by rotating the outer gear with which it meshes. Rotation of the outer gear correspondingly rotates the inner gear with which guide block gear rack  222  meshes. When plunger gear rack  224  is moved upwardly, guide block gear rack  222  is moved downwardly a distance determined by the gear ratio between the inner and outer gears of double pinion gear  252 , and vice versa. Thus, as plunger gear rack  224  is moved upwardly (or downwardly) to capture a workpiece thickness, guide block gear rack  222  is moved downwardly (or upwardly) a distance corresponding to the placement of a guide block in relation to the workpiece so as to properly position the guide block relative the workpiece. 
     In one instance as can be seen in  FIGS. 13 , removable drill guide pocket hole jig  211  has been removed, with auto-adjusting pocket hole jig docking station  210  coupled to conventional guide block  205  carried by pocket hole jig base  206 . It should be understood that auto-adjusting pocket hole jig docking station  210  can be used on a conventional pocket hole jig either with or without removable drill guide pocket hole jig  211 . 
     With additional reference to  FIGS. 14 and 15 , auto-adjusting pocket hole jig docking station  210  includes a location nub  280  formed in bottom end  218  spaced from depth stop end  230 . Referring specifically to  FIG. 15 , nub  280  is received within the top of a drill guide channel of a conventional guide block  205  and depth stop end  230  engages the top of base  206  adjacent guide block  205 . The length depth stop end  230  depends downward from bottom end  218  of housing  212  determines the height of guide block  205  within base  206 . The further plunger gear rack  224  is moved upwardly due to thicker workpieces, the further guide block gear rack  222  is moved downwardly and the further guide block  205  is moved upwardly to accommodate the measured workpiece.  FIG. 13  illustrates auto-adjusting pocket hole jig docking station  210  engaging a conventional pocket hole jig to adjust the height of guide block  205  with removable drill guide pocket hole jig  211  removed.  FIG. 15  illustrates auto-adjusting pocket hole jig docking station  210  engaging a conventional pocket hole jig to adjust the height of guide block  205  with removable drill guide pocket hole jig  211  attached. 
     Referring back to  FIGS. 9 and 11 , when removable drill guide pocket hole jig  211  is attached to auto-adjusting pocket hole jig docking station  210 , movement of guide block gear rack  222  concurrently moves depth stop member  249  to which it is removably attached. Once a work piece is measured with auto-adjusting pocket hole jig docking station  210  and depth stop member  249  is moved to the specified position, it can be locked in place by fastening members  282 . Once adjusted using auto-adjusting pocket hole jig docking station  210  ( FIG. 12 ), removable drill guide pocket hole jig  211  is removed therefrom and positioned on workpiece  270  as shown in  FIG. 16 . Depth stop member  249  engages an edge of workpiece  270  providing the appropriate distance between the edge and drill bit guide channels  247  for forming properly positioned pocket holes. 
     Referring to  FIG. 17 , a drill stop collar positioning system is also included with auto-adjusting pocket hole jig docking station  210 . Collar receiver  258  carries a stop collar  276  therein through which a base end  274  of drill bit  272  extends. As plunger gear rack  224  is moved upwardly or downwardly relative housing  212 , collar receiver  258  moves stop collar  276  upwardly or downwardly on drill bit  272 , positioning stop collar  276  appropriately for drilling pocket holes in workpiece  270  the required depth for the thickness of the workpiece used. 
     Turning now to  FIG. 18 , each of the previously described embodiments can employ a guide block  342  including a reversible channel block  344 . With additional reference to  FIG. 19 , guide block  342  is similar to any of previously described guide blocks  42 ,  142  and  242 , with the exception that guide channels formed therein include a fixed guide channel  346  and a space adjacent thereto for receiving a reversible guide block  344 . Reversible guide block  344  includes a guide channel  348  offset to one side of reversible channel block  344 . With specific reference to  FIG. 20 , it can be seen that when reversible channel block  344  inserted in one position, channel  346  and channel  348  are further apart than if reversible channel block  344  is reversed. This allows a single guide block to have more than one pocket hole pattern. Additionally, as can be seen in  FIG. 21 , multiple reversible channel blocks  344  can be provided having different sized guide holes, to provide for different size drills to be used. 
     Turning now to  FIG. 22 , an auto-adjusting pocket hole jig docking station  310  carried by a pocket hole jig base  340  having a clamping mechanism  360  and horizontal drill adjustment mechanism  390  as disclosed in U.S. Pat. No. 10,376,967 herein incorporated by reference. 
     Various changes and modifications to the embodiments herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof which is assessed only by a fair interpretation of the following claims. 
     Having fully described the invention in such clear and concise terms as to enable those skilled in the art to understand and practice the same, the invention claimed is: