Patent ID: 12209460

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

As used herein, the terms “comprises,” “comprising,” “includes,” “including,” “has,” “having” or any other variation thereof, are intended to cover a non-exclusive inclusion. For example, a process, method, article, or apparatus that comprises a list of elements is not necessarily limited to only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. Further, unless expressly stated to the contrary, “or” refers to an inclusive or and not to an exclusive or. For example, a condition A or B is satisfied by anyone of the following: A is true (or present) and B is false (or not present), A is false (or not present) and B is true (or present), and both A and B are true (or present).

In addition, use of the “a” or “an” are employed to describe elements and components of the embodiments herein. This is done merely for convenience and to give a general sense of the inventive concept. This description should be read to include one or more and the singular also includes the plural unless it is obvious that it is meant otherwise.

Further, use of the term “plurality” is meant to convey “more than one” unless expressly stated to the contrary.

As used herein, qualifiers like “substantially,” “about,” “approximately,” and combinations and variations thereof, are intended to include not only the exact amount or value that they qualify, but also some slight deviations therefrom, which may be due to manufacturing tolerances, measurement error, wear and tear, stresses exerted on various parts, and combinations thereof, for example.

The use of the term “at least one” or “one or more” will be understood to include one as well as any quantity more than one. In addition, the use of the phrase “at least one of X, V, and Z” will be understood to include X alone, V alone, and Z alone, as well as any combination of X, V, and Z.

The use of ordinal number terminology (i.e., “first”, “second”, “third”, “fourth”, etc.) is solely for the purpose of differentiating between two or more items and, unless explicitly stated otherwise, is not meant to imply any sequence or order or importance to one item over another or any order of addition.

Finally, as used herein any reference to “one embodiment” or “an embodiment” means that a particular element, feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment. The appearances of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.

Referring now to the drawings,FIG.1illustrates a drilling apparatus10for creating a weep hole12(seeFIG.4D) in a hollow core structural component14. The drilling apparatus10may be used for drilling the weep hole12and removing any material debris16generated during a drilling process as depicted inFIGS.4A-4D,FIGS.5A-5D, andFIGS.6A-6F. Broadly, the drilling apparatus10may include a drill bit20, connected to a drill21.

Referring toFIG.1-3, the drill bit20may have a shank22, a neck23, and a body24. The shank22is shown to have a hex shank, but it should be understood that the shank22may be a brace shank, a straight shank, a square shank, a SDS shank, a threaded shank or any other type of shank that would securely attach the drill bit20to the drill21. The neck23of the drill bit20may have a substantially cylindrical shape, although the shape of the neck23can vary. In one embodiment, the neck23has a diameter equal to or less than a diameter of the body24. The length of the neck23may vary and be dependent upon the dimension of the hollow core structural component60.

The body24may include a cutting edge29configured to cut and remove material from the hollow core structural component60, and flutes25that lift the material debris16out of the weep hole12. The length and diameter of the body24will vary and will be determined by the depth and diameter requirements for the weep hole12. The drill bit20also includes an internal fluid passageway27so that pressurized fluid can enter a fluid inlet26, travel through the internal fluid passageway27, and exit a fluid outlet28. The fluid can be a gas or liquid. For example, the fluid can be air. The fluid inlet26will be located in a position at or near the shank22so that when the shank22is firmly seating in a chuck32of the drill21the fluid inlet26will be fluidly connected to a fluid outlet within the drill21. The internal fluid passageway27may be a generally cylindrical void that extends from the fluid inlet26to the fluid outlet28. The diameter of the internal fluid passageway27will be determined based on ensuring that an adequate volume of pressurized fluid is able to flow through the internal fluid passageway27at a specified fluid pressure without jeopardizing the structural integrity of the drill bit20. The fluid outlet28may be located at any location along an external surface of the body24or the neck23of the drill bit20so long as the fluid outlet28can direct fluid around the weep hole12to remove the material debris16as described herein. It may, however, be preferable to position the fluid outlet within the body24so as to be closer to the cutting edge29to greater control the removal of the material debris16when releasing pressurized fluid. The size and shape of the fluid outlet28may be designed to direct pressurized fluid exiting the fluid outlet28in order to maximize the removal of material debris16located near the weep hole12.

The drill21includes the chuck32that is configured to connect to the drill bit20, and a motor (not shown) included within a housing33. In the example shown, the drill21is powered by electricity, although other forms of powering the drill21can be used. For example, the drill21can be a pneumatic drill powered by pressurized fluid. In some embodiments, the drill21is portable and adapted to be utilized by an operator to manually form the weep hole12. In this embodiment, the drill21includes a handle34that can be gripped by the operator. In other embodiments, the drill21is connected to a guide and operated as part of a larger machine to form the weep hole12. In some embodiments, the drilling apparatus10may include multiple drills21connected to multiple bits20that are guided simultaneously (or separately) to form multiple weep holes12. In some embodiments, the drill21is a hammer drill, while in other embodiments, the drill21is not a hammer drill.

In the example shown, the drill21is connected to a power source40that provides the energy to enable the drill21to rotate the drill bit20. The power source40may provide power in the form of electric, hydraulic, or pneumatic power. The drilling apparatus10includes a power switch42that controls the flow of power from the power source40to the drill21. AlthoughFIG.1, depicts the power switch42as a trigger switch located near the handle34, it should be understood by a person skilled in the art that the power switch42does not need to be fixed to the drill21. The power switch42may be operated manually in the form of a push button switch, a toggle switch, a rotary cam switch, a valve, or any other similar device. Alternatively, the power switch may be operated autonomously by way of computer software instruction. When the power switch42is switched on, power from the power source40is transmitted to the drill21, causing the drill21to rotate the chuck32and the drill bit20in a desired direction. The power switch42may allow regulation of the power being supplied to the drill21from the power source40to provide control of a rotational speed and a torque for the drill21. Alternatively, the rotational speed and torque of the drill may be controlled by other mechanisms.

The drill21is also connected to a pressurized fluid source50that provides pressurized fluid to the fluid outlet28of the drill bit20via the drill21. The pressurized fluid source50may be a pressurized fluid tank or a fluid compressor. The pressurized fluid source50may include a pressure regulator capable of providing adjustability of the pressure contained within or released from the pressurized fluid source50. The pressurized fluid source50may be connected to the drill21via a hose51. The drilling apparatus10also includes a pressurized fluid actuator52that may allow pressurized fluid to flow from the pressurized fluid source50, to the fluid inlet26, through the internal fluid passageway27, and exit the fluid outlet28. The pressurized fluid actuator52may be actuated by electric, hydraulic, pneumatic, or human power. For example, the pressurized fluid actuator may be implemented as a valve that is controlled via a trigger that is placed adjacent to the handle34, as shown inFIG.1. When the pressurized fluid actuator52is actuated, pressurized fluid from the pressurized fluid source50is released into the air inlet26. The drill21may have a regulator (not shown) at some location between the pressurized fluid source50and the fluid inlet26to allow for the control of the fluid pressure that exits the fluid outlet28.

Turning now toFIGS.4A-4D, an exemplary method of use of the drilling apparatus10will be described. As shown inFIG.4A, first the drilling apparatus10may be positioned so that the drill bit20is situated in a direction for drilling with the body24of the drill bit20at a location for drilling the weep hole12in a hollow core structural component14. The hollow core structural component14may have one or more external surfaces62and one or more internal surfaces64forming a cavity66in the hollow core structural component14. In one embodiment, as shown inFIGS.4A-4D, the hollow core structural component14may have a first one or more external surface62aand a second one or more external surface62b. However, it will be understood that the hollow core structural component60may have more or fewer external surfaces62.

The operator may engage the power switch42to provide power to the drill21from the power source40so that the drill21rotates the drill bit20in a desired rotational direction70and at a rotational speed for drilling the weep hole12through the hollow core structural component14. A first directional force72amay be applied to the drill21in a desired direction for drilling the weep hole12.

As illustrated inFIG.4B, the first directional force72amay be applied to drive the drill bit20to drill from a first one or more external surface62a, through the material of the hollow core structural component14, through a first one or more internal surface64a, and into the cavity66. The drilling process may cause material debris16from a first drilled hole65to be deposited just below the first drilled hole65and in a general location of where the weep hole12is to be created.

As depicted inFIG.4C, the first directional force72amay be applied to drive the drill21through the cavity66, and allow the drill bit20to drill through a second one or more internal surface64b, through the material of the hollow core structural component14, and through a second one or more external surface62b. After the drill bit20drills through the second one or more external surface62b, the fluid outlet28may be positioned so that the fluid outlet28is proximate to the second one or more internal surface64b. The pressurized fluid actuator52may be actuated, causing pressurized fluid to flow from the pressurized fluid source50, through the hose51, the internal fluid passageway27, and exit the fluid outlet28while the drill bit20continues to rotate in the desired rotational direction70. The pressurized fluid actuator52may allow the pressurized fluid to continue to flow through the drill bit20, and the drill21of the drilling apparatus10and out the fluid outlet28until all loose, uncured concrete, material debris16is substantially removed from the immediate area surrounding the weep hole12. The pressurized fluid actuator52should allow pressurized fluid flow while the drill bit20continues to rotate one or more revolutions to ensure the pressurized fluid is directed at the material debris16about a parameter of the weep hole12. A second directional force72bmay be applied to the drill21so that the fluid outlet28is moved in and out of the weep hole12. The second directional force72bmay add a third dimension to the position of the fluid outlet28which may assist with the removal of material debris16proximate to the weep hole68.

As shown inFIG.4D, the pressurized fluid actuator52may be deactivated, stopping the flow of pressurized fluid through the drilling apparatus10. The power switch42may also be turned off, cutting off the power to the drill21, and stopping the rotation of the drill bit20. A third directional force72cmay be applied to the drilling apparatus10until the drill bit20is entirely removed from the hollow core structural component14. The result of the process is the creation of the weep hole12in the hollow core structural component14free of any material debris16that might interfere with the function of the weep hole12. When the hollow core structural component14is not fully cured when the weep hole12is formed, then the hollow structural component14may be allowed to cure prior to installation as a structural component in a structure, such as a building, road, or the like.

FIGS.5A-5F, illustrates several perspective views from within the cavity66of the hollow core structural component14, showing steps of an exemplary method for forming the weep hole12substantially free of material debris16, in accordance with the present disclosure.FIG.5Ashows the cavity66of the hollow core structural component14before the method has been initiated toward the creation of the weep hole68. There may be the presence of loose, material debris16within the cavity66along the lower portion of the one or more internal surfaces64prior to the drilling process as a result of forming the hollow core structural component14.

As shown inFIG.5B, a force may be applied to the drill21in the direction of the weep hole12causing the drill bit20to drill through the first one or more external surface62and the first one or more internal surface64. The drill bit20continues to rotate inside the cavity66after the weep hole12has been formed. Additional material debris16may collect beneath the first drilled hole65as a result of the drilling process.

As depicted inFIG.5C, the force may continue to be applied to the drill21in the direction of the weep hole12causing the drill bit20to drill through the second one or more internal surface64and a second one or more external surface62. Additional material debris16may accumulate around the weep hole12as a result of the drilling process.

As shown inFIG.5D, the drill bit20may be positioned so that the fluid outlet28is proximate to the second one or more internal surface64. The pressurized fluid actuator52may be actuated, allowing pressurized air to flow through the internal fluid passageway27while the drill21continues to rotate the drill bit20. Pressurized fluid exits the fluid outlet28with enough force to reposition any loose, material debris16a sufficient distance from the weep hole12. The fluid outlet28may be directed generally perpendicular to the drill bit20and designed to focus the pressurized fluid exiting the fluid outlet28away from the weep hole12. The drill bit20may be rotated one or more revolutions while pressurized fluid is being release from the fluid outlet28to ensure all material debris16around the weep hole12is sufficiently removed from the immediate area. The drill bit20may be moved in and out of the weep hole12to assist the removal of material debris16. By moving the drill bit20in and out of the weep hole12, the pressurized fluid exiting the fluid outlet28may exert a variety of forces on the material debris16that may not be experienced by a stationary drill bit20.

As shownFIG.5E, the pressurized fluid actuator52may be deactivated so that pressurized fluid is no longer flowing through the drill bit20and the drill21of the drilling apparatus10. The power switch42may also be turned off, causing the drill21to stop rotating the drill bit20. A force may be applied to the drill21opposite of the drilling direction until the drill bit20is removed from the hollow core structural component14.

FIG.5F, depicts the cavity66of the hollow core structural component14once the drill bit20has been removed. As illustrated inFIG.5F, the weep hole12is free from any loose material debris16that might interfere with the function of the weep hole12.

Referring now toFIG.6, a drilling method100provides an exemplary method for forming the weep hole12that is substantially free of material debris16, within the hollow core structural component14in accordance with the present disclosure. In step102of the drilling method100, an operator may identify a desired location to form the weep hole12in the cavity66of the hollow core structural member14. The ideal location for the weep hole12would be the lowest area of the one or more internal surfaces64, but may be any location within the hollow core structural component14that would allow moisture to be removed from the cavity66. The desired location for the weep hole12may only be accessible by first drilling through the opposite side of the hollow core structural component14.

In step104of the drilling method100, the cutting edge29of the drill bit20may be placed at the desired location for the weep hole12. The drill21may need to be positioned so that the drill bit20will be driven in the desired direction for the weep hole12. Next, in step106of the drilling method100, the drill21may be activated with power to cause the drill bit20to rotate, and pressure may be applied to the drill21to allow drill bit20to bore the weep hole12in the hollow core structural member14. The drill21will be activated by turning on the power switch42which allows power to be provided to the drill21from the power source40. In step108, pressure may continue to be applied to the drill21until the drill bit20has bored the weep hole12. The amount of pressure required may depend on the characteristics of material of the hollow core structural component14, the rotational speed of the drill bit20, and the characteristics of the drill bit20. Depending on the location of the weep hole12, the drill bit20may need to bore a hole in one or more layers of the hollow core structural component14before boring the weep hole12.

As detailed in Step110, power may be maintained to the drill21, while the drill bit20may be repositioned so that the fluid outlet28is proximate to the one or more internal surfaces64, and the pressurized fluid actuator52is activated to release pressurized fluid form the pressurized fluid source50. In step112, power may be maintained to the drill21and releasing the pressurized fluid, while the drill bit20is repositioned in and out of the weep hole12until all material debris16has been removed from the immediate area. By performing this action, pressurized fluid will be released in a 360-degree spray about the drill bit20and at various points vertically along a drilling axis within the range of the in and out motion. The pressurized fluid will apply forces on the material debris16immediately surrounding the weep hole12. These forces may cause the material debris16to be relocated substantially away from the weep hole12. In one embodiment, the pressurized fluid actuator52should be engaged continuously for at least one revolution of the drill bit20to ensure pressurized fluid is released in all directions about the drilling axis.

Lastly, in step114of the drilling method100, Once the area immediately around the weep hole12has been clear of any loose, material debris16, power may be shut off to the drill21, the pressurized fluid actuator52may be deactivated to stop pressurized fluid from flowing from the pressurized fluid source50, and the drill bit20may be removed from the weep hole12.

While the present disclosure has been described in connection with certain embodiments so that aspects thereof may be more fully understood and appreciated, it is not intended that the present disclosure be limited to these particular embodiments. On the contrary, it is intended that all alternatives, modifications and equivalents are included within the scope of the present disclosure. Thus the examples described above, which include particular embodiments, will serve to illustrate the practice of the present disclosure, it being understood that the particulars shown are by way of example and for purposes of illustrative discussion of particular embodiments only and are presented in the cause of providing what is believed to be the most useful and readily understood description of procedures as well as of the principles and conceptual aspects of the presently disclosed methods and compositions. Changes may be made in the structures of the various components described herein, or the methods described herein without departing from the spirit and scope of the present disclosure.