Stud Punch

Abstract

A stud punch device is disclosed that can be configured to punch holes in metal studs that have been placed at various elevations in a structure. The disclosed stud punch can be configured to adjust its elevation so that the operator of the device can sand on a floor while punching the cut outs rather than having to climb a ladder or scaffolding to operate the device near the location of the hole(s) to be punched out by the stud punch device.

Claims

1. An apparatus for punching holes in metal studs, comprising: a head unit having a proximal end and a distal end, wherein said distal end of said head unit includes a die, wherein said die includes a proximal end and a distal end, wherein said proximal end of said head unit includes a punch, and wherein said die and said punch are configured to work in conjunction to punch holes in metal studs; a first pole having a proximal end and a distal end, wherein said distal end of said first pole is connected to said head unit; a second pole having a proximal end and a distal end, wherein said distal end of said second pole is connected to said head unit with a linkage, wherein said linkage is configured to permit said punch to move from an unactuated position to an actuated position within said head unit when moving said second pole from a proximal position to a distal position; and wherein said apparatus has an overall length that extends proximally in a perpendicular direction from said proximal end of said die and interfaces a reference line that extends horizontally from said distal end of said first pole, wherein such overall length is at least 24 inches.

2. The apparatus of claim 1, wherein a third pole connects said proximal end of said first pole to said proximal end of said second pole in a manner that permits said second pole to move relative to said first pole.

3. The apparatus of claim 2, wherein said third pole extends in a downward direction from said proximal end of said second pole when said second pole is positioned such that said punch is in said actuated position.

4. The apparatus of claim 1, wherein said first pole and said second pole are each extendable so as to adjust said overall length of said apparatus.

5. The apparatus of claim 4, wherein said first pole and said second pole each comprise at least two telescopic sections.

6. The apparatus of claim 5, wherein said first pole and said second pole each comprise three telescopic sections.

7. The apparatus of claim 6, wherein said distal end of said first pole is connected to said distal end of said head unit and said distal end of said second pole is connected to said proximal end of said head unit.

8. The apparatus of claim 7, wherein said connection between said distal end of said first pole and said head unit includes a fixed connection.

9. The apparatus of claim 4, wherein said overall length is at least 45 inches.

10. The apparatus of claim 9, wherein said overall length is at least 70 inches.

11. The apparatus of claim 1, wherein said reference line that extends proximally in a perpendicular direction from said proximal end of said die is parallel to a reference line that extends along the centerline of said first pole.

12. The apparatus of claim 1, wherein said apparatus is configured so as to permit a user standing at a proximal location on a floor of a building to actuate said punch relative to said die to create a punch out in a top plate of a stud, wherein said top plate of said stud is located at an elevation of at least eight feet above said floor.

13. An apparatus for punching holes in metal studs, comprising: a head unit that includes a die and a punch, wherein said die and said punch are configured to work in conjunction with one another to punch holes in metal studs; a first pole having a proximal end and a distal end, wherein said distal end of said first pole is connected to said head unit and wherein said first pole is extendable; a second pole having a proximal end and a distal end, wherein said distal end of said second pole is connected to said head unit and wherein said second pole is extendable; wherein said first pole and said second pole are configured to move relative to one another so as to actuate said punch relative to said die; and wherein said apparatus is configured so as to permit a user standing at a proximal location on a floor of a building to actuate said punch relative to said die to create a cut out in the top plate of a metal stud, wherein said top plate of said metal stud is located at least eight feet above said floor of said building.

14. The apparatus of claim 13, wherein a third pole connects said proximal end of said first pole to said proximal end of said second pole.

15. The apparatus of claim 13, wherein said first pole and said second pole each comprise at least two telescopic sections.

16. The apparatus of claim 15, wherein said first pole and said second pole each comprise three telescopic sections.

17. The apparatus of claim 13, wherein said die and said first pole each includes a centerline, wherein a reference line projected distally from said centerline of said die is parallel to a reference line project along said centerline of said first pole.

18. An apparatus for punching holes in metal studs, comprising: a head unit having a proximal end and a distal end, wherein said head unit includes a die and a punch that are configured to work in conjunction to punch holes in metal studs; a first pole having a proximal end and a distal end, wherein said distal end of said first pole is connected to said head unit; a second pole having a proximal end and a distal end, wherein said distal end of said second pole is connected to said head unit; and wherein said die and said first pole are configured such that a reference line projected distally from the center line of said die and a reference line projected distally from the center line of said first pole interface at a distal location above said apparatus to form an interior angle falling within the range of from 0 degrees to 45 degrees.

19. The apparatus of claim 18, wherein said die is located at said distal end of said heat unit.

20. The apparatus of claim 19, wherein said distal end of said first pole is connected to said distal end of said head unit.

21. The apparatus of claim 18, wherein said apparatus is configured so as to permit a user standing at a proximal location on a floor of a building to actuate said punch relative to said die while said head unit is located at a distal location at least eight feet above said floor of said building.

22. The apparatus of claim 18, wherein a third pole connects said proximal end of said first pole to said proximal end of said second pole.

23. The apparatus of claim 18, wherein said interior angle falls within the range of 8 degrees to 12 degrees.

24. The apparatus of claim 23, wherein said interior angle is 10 degrees.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0017] FIG. 1 depicts an upper-left-side perspective view of an illustrative embodiment of the invention in an unactuated position with the first and second poles fully retracted.

[0018] FIG. 2 depicts an upper-left-side perspective view of an illustrative embodiment of the invention in an actuated position with the first and second poles fully retracted.

[0019] FIG. 3 depicts an upper-left-side perspective view of an illustrative embodiment of the invention in an unactuated position with the first and second poles partially extended.

[0020] FIG. 4 depicts an upper-left-side perspective view of an illustrative embodiment of the invention in an actuated position with the first and second poles partially extended.

[0021] FIG. 5 depicts an upper-left-side perspective view of an illustrative embodiment of the invention in an unactuated position with the first and second poles fully extended.

[0022] FIG. 6 depicts an upper-left-side perspective view of an illustrative embodiment of the invention in an actuated position with the first and second poles fully extended.

[0023] FIG. 7 depicts an upper-left-side perspective view of an illustrative embodiment of the invention in a stowed position.

[0024] FIG. 8 depicts a left side elevation view of an illustrative embodiment of the invention.

[0025] FIG. 9 depicts a left side elevation view of an illustrative embodiment of the invention.

[0026] FIG. 10 depicts a left side elevation view of an illustrative embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0027] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to certain embodiments thereof and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended, such alterations, further modifications and further applications of the principles of the invention as described herein being contemplated as would normally occur to one skilled in the art to which the invention relates.

[0028] FIGS. 1 through 10 depict illustrative embodiments of the invention in several configurations. Disclosed in FIGS. 1-7, for example, is an illustrative stud punch 1 of the invention that can include a head unit 10 that has a proximal end 12 and a distal end 14. The distal end 14 of the head unit 10 can include a die 14 and the proximal end 12 of the head unit 10 can include a punch. The head unit 10 can occupy a c-shape, as depicted in FIGS. 1-7, but alternatively, can occupy any suitable shape that can facilitate use of the inventions disclosed herein.

[0029] As also shown in FIGS. 1-7, an illustrative embodiment of the invention can include a first pole 30 that has a proximal end 32 and a distal end 34. The distal end 34 of the first pole 30 can be connected to the distal end 14 of the head unit 10. This connection can be a fixed connection, such as can be established by welding the head unit 10 (or a tab extending therefrom) to the first pole 30. Although a welded connection is depicted in the Figures, any suitable connection type can be used, such as a releasable connection (created by using pins and/or bolts and screw, for example).

[0030] Embodiments of the invention can also include a second pole 50 that has a proximal end 52 and a distal end 54. The distal end 54 of the second pole 50 can be connected to the proximal end 12 of the head unit 10 by way of a linkage 25 that permits the second pole 50 and the punch 15 to move in relation to the head unit 10 so as to permit the punch 15 to move from an unactuated position (depicted in FIGS. 1, 3, and 5) to an actuated position (depicted in FIGS. 2, 4, and 6) where it contacts the die 20 to establish a cut out in a stud, such as a metal stud when such stud is located between the punch 15 and the die 20. In certain embodiments, the invention can be used to create cut outs or knock outs in studs, made of metal, wood, fiberglass, and the like) of any size necessary to run wiring, conduit, and/or piping through the walls or plates of the studs. Illustrative such metal studs are disclosed in U.S. Pat. No. 5,596,859 to Horton, et al, which is incorporated herein by reference as if fully set forth herein. In certain embodiments, the size, such as the diameter, of the punch 15 and/or die 20 can be varied, such as where the size of the cut out needs to vary to accommodate a certain use, such as a certain size of pipe. Illustratively, the punch 15 and/or die 20 can be interchanged in order to accommodate these desires.

[0031] In certain embodiments, the first pole 30 can be hollow and can include several sections that permit the extension (and retraction) of the first pole 30. For example, the first pole 30 can include a first section 36A located at the proximal end 32 of the first pole 30. The first pole 30 can also include a third section 36C that is located at the distal end 34 of the first pole 30, as well as a second section 36B that is located in between the first section 36A and the third section 36B. The third section 36C can be nested within the second section 36B, which in turn can be nested within the first section 36A in a manner that permits the second section 36B to extend from and retract within the first section 36A and that further permits the third section 36C to extend from and retract within the second section 36B. Illustratively, the first section 36A can occupy an outer diameter of 1.250 inches and an inner diameter of 1.150 inches, the second section 36B can occupy an outer diameter of 1.125 inches and an inner diameter of 1.025 inches, and the third section 36C can occupy an outer diameter of 1.000 inches, and an inner diameter of 0.900 inches. These dimensions are illustrative only, and any suitable dimensions can be implemented to provide the invention.

[0032] Apertures that can interface with spring pins 60 can be used to interlock the sections 36A, 36B, 36C, of the first pole 30 from their extended to retracted positions, as desirable. Suitable apertures that can interface with spring pins include those disclosed in U.S. Pat. Nos. 6,089,247 and 7,445,398, which are incorporated herein by reference in their entirety. Although the depicted embodiments utilize apertures that can interface with spring pins 60 to provide for the extension of the first pole 30 and second pole 50 to various locations, any suitable technology can be used to permit the extension of the first pole 30 and the second pole 50 to a plurality of locations. Instead of apertures that can interface with spring pins 60, for example, any type of suitable interlocking mechanism can be used such as those disclosed in U.S. Pat. Nos. 4,324,502, 6,203,064, 6,461,074, 7,344,320, 8,006,711, and or U.S. Patent Pub. No. 2014/0150834, of which each is incorporated by reference as if fully set forth herein.

[0033] Illustratively, the second pole 50 can also be hollow and include several sections that permit the extension (and retraction) of the second pole 50. For example, the second pole 50 can include a first section 56A located at the proximal end 52 of the first pole 50. The second pole 50 can also include a third section 56C (best depicted in FIGS. 5-6) that is located at the distal end 54 of the second pole 50, as well as a second section 56B that is located in between the first section 56A and the third section 56B. The third section 56C can be nested within the second section 56B, which in turn can be nested within the first section 56A in a manner that permits the second section 56B to extend from and retract within the first section 56A and that further permits the third section 56C to extend from and retract within the second section 56B. Illustratively, the first section 56A can occupy an outer diameter of 1.250 inches and an inner diameter of 1.150 inches, the second section 56B can occupy an outer diameter of 1.125 inches and an inner diameter of 1.025 inches, and the third section 56C can occupy an outer diameter of 1.000 inches, and an inner diameter of 0.900 inches. These dimensions are illustrative only, and any suitable dimensions can be implemented to provide the invention.

[0034] Apertures that can interface with spring pins 60 can be used to interlock the sections 56A, 56B, 56C, of the second pole 50 in order to from their extended to retracted positions, as desirable. Suitable apertures that can interface with spring pins 60 include those disclosed in U.S. Pat. Nos. 6,089,247 and 7,445,398, which are incorporated herein by reference in their entirety. Although the depicted embodiments utilize apertures that can interface with spring pins 60 to provide for the extension of the first pole 30 and second pole 50 to various locations, any suitable technology can be used to permit the extension of the first pole 30 and the second pole 50 to a plurality of locations. Instead of apertures that can interface with spring pins 60, for example, any type of suitable interlocking mechanism can be used such as those disclosed in U.S. Pat. Nos. 4,324,502, 6,203,064, 6,461,074, 7,344,320, 8,006,711, and or U.S. Patent Pub. No. 2014/0150834, each of which is incorporated by reference as if fully set forth herein.

[0035] In additional embodiments, and suitable implementation can be used to extend and retract the first pole 30 and the second pole 50. In certain embodiments, for example, the first pole 30 and second pole 50 can be fixed and be interchanged to provide for various lengths of the first pole 30 and the second pole 50.

[0036] Illustrative embodiments of the invention can also include a third pole 100 that can be attached to the proximal end 32 of the first pole 30 and the proximal end 52 of the second pole 52 in a manner that allows the second pole 52 to move bi-directionally relative to the first pole 30. Such bi-directional movement provides for the actuation of the punch 15 between an unactuated state (when the second pole 50 is in a proximal location) and an actuated state (when the second pole is in a distal location). The third pole 100 can be attached to the proximal end 32 of the first pole 30 and the proximal end of the second pole 52 using a linkage 90 that includes a plate 90C and two pairs of bolts and nuts 90A, 90B that extend through the plate 90C, first pole 30, and the second pole 50, and the third pole 100. In other embodiments, however, any suitable linkage can be used to connect the third pole 100 with the first pole 30 and the second pole 50.

[0037] Illustratively, the third pole 100 can include a handle 105 and pad 105A for gripping. The first pole can include a pad 82 for gripping, as well as a bar 42 that includes a pad 42A. During use of the illustrative stud punch 1, a user (not depicted) can place the pad 42A against the front of his leg in the area of his waist. He can then hold the device with his left hand using the pad 82 located on the first pole 30. He can then grab the pad 105A on the handle 105 of the third pole 100 with his right hand. Once a user so orients himself with the illustrative stud punch 1, he can place the head unit 10 around the top plate of a metal stud and then actuate the punch 15 by moving the handle 105 of the third pole 100 in a distal (or downward direction) (as depicted in FIGS. 2, 4, and 6) and apply sufficient force to create a cut out in the metal stud. The user can then move the punch 15 to a non-actuated position (such as is shown in FIGS. 1, 3, and 5), and then move the stud punch 1 to a different location on the same or a different stud wall and create a separate cut out in the top plate of the metal stud.

[0038] In certain embodiments, the linkage 25 that connects the heat unit 10 to the second pole 50 can include a stop 27 that prevents the second pole 50 and the linkage 25 from moving into a lockout position when moving the second pole 50 in a proximal direction relative to the first pole 30. Without this stop 50, at times, the second pole 50 and the linkage 25 can move into a lockout position, which when in this position, prevents a user from actuating the punch 15 by moving the second pole 50 in a distal direction in relation to the first pole 30. This is undesirable because the user must manipulate the second pole 50 to alleviate the lockout position so as to continue use of the stud punch 1. Frequent lockouts of the stud punch 1 is undesirable because of the additional effort and time needed to overcome lockout and continue use of the stud punch 1.

[0039] FIG. 7 shows an illustrative stud punch 1 in its stowed position. To facilitate the depicted position, the first pole 30 and the second pole 50 are first placed in their shortest positions. Then, one of the spring pins is depressed to allow the second pole 50 to extend to a slightly longer state and the handle 105 of the third pole 100 is then moved until pointing in a distal direction and the first pole 30 and the second pole 50 are parallel. This positioning provides a reduced footprint for the stud punch 1 so as to facilitate its storage between uses. The stud punch 1 can be stored in packaging, if desirable, or can be held together with clips or ties, if preferred.

[0040] FIGS. 8-10 depict side elevation views of the stud punch 1 in three illustrative positions. In FIG. 8, for example, the third section 36C of the first pole 30 is nested inside the second section 36B of the first pole 30 and the second section 36B of the first pole 30 is nested inside of the first section 36A of the first pole 30. Similarly, the third section 56C of the second pole 50 is nested inside the second section 56B of the second pole 50 and the second section 56B of the second pole 50 is nested inside of the first section 56A of the second pole 50. In this illustrative position, the stud punch 1 has an overall length L that extends proximally in a perpendicular direction from the proximal end 22 of the die and interfaces a reference line that extends horizontally from the distalmost end 32A of the first pole 30. As depicted in FIG. 8, the overall length L is at least 45 inches, but can be any desirable dimension, including any dimension from 12 inches to 55 inches, such as 24 inches, 36 inches, 50 inches, and the like.

[0041] In FIG. 9, for example, the third section 36C of the first pole 30 is nested inside the second section 36B of the first pole 30 and the second section 36B of the first pole 30 is extended from the first section 36A of the first pole 30. Similarly, the third section 56C of the second pole 50 is nested inside the second section 56B of the second pole 50 and the second section 56B of the second pole 50 is extended from the first section 56A of the second pole 50. In this illustrative position, the stud punch 1 has an overall length L that is at least 70 inches, but can be any desirable dimension, including any dimension from 70 inches to 85 inches, such as 73.6 inches.

[0042] In FIG. 10, for example, the third section 36C of the first pole 30 is extended from the second section 36B of the first pole 30 and the second section 36B of the first pole 30 is extended from the first section 36A of the first pole 30. Similarly, the third section 56C of the second pole 50 is extended from the second section 56B of the second pole 50 and the second section 56B of the second pole 50 is extended from the first section 56A of the second pole 50. In this illustrative position, the stud punch 1 has an overall length L that is at least 95 inches, but can be any desirable dimension, including any dimension from 90 inches to 105 inches, such as 97.2 inches.

[0043] As also depicted illustratively in FIGS. 8-10, the first pole 30 can have a centerline CLFP that can be projected as a reference line to a location above the stud punch 1 until it intersects with a reference line CLD that extends in a distal direction perpendicular from the center of the die 20. The intersection of these two lines can form an interior angle a that falls within a range of 0 degrees up to 45 degrees. In certain embodiments, this range can fall within a range of 8 degrees to 12 degrees, such as to provide an interior angle a of 10 degrees. In other embodiments, however, any suitable angle may be provided. In certain embodiments, in fact, the reference line established by the centerline of the die CLD can be parallel to the reference line that is established by the centerline CLFP of the first pole 30.

[0044] The illustrative stud punch 1 can be made of any suitable materials. For example, the first pole 30, second pole 30, and third pole 30 can be made of carbon steel, aluminum, stainless steel, fiberglass, and the like. It is desirable to provide a light weight stud punch 1 that is still durable and that can impart the forces necessary to make the appropriate cut outs. In similar fashion, the head unit 10, the die 20, and the punch 15 can also comprise any suitable material, such as carbon steel, stainless steel, or aluminum. The hand pads 82, 105A, and the waist pad 42 can also include any suitable material, such as any suitable foam, e.g. polyvinyl chloride form, rubber, and the like. The linkages 25, 90 can similarly be made of any suitable materials, such as carbon steel, aluminum, stainless steel, fiberglass, and the like. Illustratively the spring pins used in the apertures that interface with spring pins 60 can be made of any suitable material, such as carbon steel, aluminum, stainless steel, or fiberglass.

[0045] Although the illustrative embodiments of the invention depicted in FIGS. 1-10 show the distal end 34 of the first pole 30 as being connected to the distal end 14 of the head unit 10, in other embodiments, the distal end 34 of the first pole 30 can be connected at any suitable location on the head unit 10, including but not limited to the proximal end 14 of the head unit 10. Similarly, the distal end 54 of the second pole 50 can be connected at any suitable location on the head unit 10, such as the distal end 14 of the head unit, and can also be connected to just the punch 15, if desired.

[0046] In yet other embodiments, the locations of the die 20 and the punch 15 can be reversed, such that the punch is located in the distal end 14 of the head unit 10 and the die is located in the proximal end 12 of the head unit 10. In such embodiments, for example, the linkage 25 can link the distal end 34 of the first pole 30 to the distal end 14 of the head unit 10 so as to permit manipulation of the punch 15 in proximal (actuated) and distal (unactuated) locations, and the second pole 50 can remain fixed in relation to the movement of the first pole 30. In certain embodiments, the distal end 34 of the first pole 30 can be connected directly to the punch 15. Yet additional embodiments of the invention can provide for movement of the die 20 in relation to a stationary punch 15, if desirable. Any suitable implementation of the stud punch 1 can be made that permits actuation of the punch 15 and die 20 to create a cut out in the top plate of a stud located at least 8 feet high by a user who is standing on the floor of a building. In certain embodiments, the stud punch 1 can by used by a user standing on the floor of a building to make cut outs in the top plate of a metal stud at elevations above 8 feet, such as 10 feet, 12 feet, 16 feet, and higher.

[0047] As illustrated in FIGS. 1-10, the stud punch 1 can be actuated by a user who manipulates the third pole 100 (using the third pole handle 105A). In other embodiments, however, any suitable mechanism can be used to actuate the stud punch 1. For example, a motor can be used to actuate the punch 15. Such motor can be located near or on the head unit 10 and can be powered with AC power or with DC current from a battery, such as a rechargeable battery. In other embodiments, the punch 15 can be actuated with hydraulics, with such hydraulics being manipulated by a user (such as by pumping the third pole handle 105), pneumatically (such as by using a portable air compressor), electrically (such as by using AC power or a DC battery, such as a rechargeable battery), or with CO2 cartridge technology. Illustrative such technologies are disclosed in U.S. Pat. Nos. 7,296,721, 7,797,840, 9,199,389, 10,195,755, 11,148,312, and/or U.S. Patent App. Pub. Nos. 2005/0056680 and/or 2023/0107079, each of which is incorporated herein by reference in its entirety. In certain embodiments, for example, of the stud punch 1 need not include a third pole 100. In such illustrative embodiments, a user can manipulate the second pole 50 in relation to the first pole using his arms or other suitable mechanical means, as discussed above. In other embodiments, the stud punch 1 may only occupy a single pole, such as the first pole 30, and actuation of the punch 15 and die 20 can be made using hydraulics or pneumatic force, as discussed above.

[0048] All publications cited herein are hereby incorporated by reference in their entirety as if each had been individually incorporated by reference and fully set forth.

[0049] While the invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that only the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the invention are desired to be protected.