PLUGS WITH DIMENSIONAL TOLERANCE FOR FILLING PERFECTLY AND IMPERFECTLY DRILLED HOLES
20170159691 ยท 2017-06-08
Assignee
Inventors
Cpc classification
F16B19/004
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F16B13/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
Abstract
Plugs with a high dimensional tolerance of about +/33 percent for successfully plugging holes even if the holes were miss-drilled to have diameters that vary up to thirty-three percent smaller or larger from the specified hole/plug size of any chosen material, tapered to approximately one degree or un-tapered, having a three-dimensionally textured surface made up of elements imparted upon a surface of the plug causing the plug to exert a strong hold-in force of outwardly directed pressure against a side wall of a drilled hole into which the plug is installed keeping the plug within the drilled hole so that the plug does not protrude out of the hole preventing tripping hazards when the hole is drilled in walking surfaces all without requiring the addition of a glue, special tools, or special fasteners. The plug has a 30 second or less installation time.
Claims
1. A plug for plugging perfectly and imperfectly drilled holes, comprising: a plug having a dimensional tolerance of about +/33 percent, said plug having a textured surface made up of three-dimensional elements created upon said plug, said elements causing said plug to exert a strong hold-in force of outwardly directed pressure against the side wall of the drilled hole into which said plug will be installed causing said plugs, when used to plug holes, to successfully plug holes miss-drilled to have diameter sizes that vary up to thirty-three percent smaller or larger from the specified hole/plug size.
2. The plug, as recited in claim 1, wherein said plug has a given diameter size ranging from about (0.125) diameter to 1 (1.5),
3. The plug, as recited in claim 2, wherein said plug has a given diameter size ranging from about a range of (0.25) to (0.50)
4. The plug, as recited in claim 3, wherein said three-dimensional elements are protuberances.
5. The plug, as recited in claim 4, wherein said protuberances are about the circumferential surface of said plug.
6. The plug, as recited in claim 5, wherein said protuberances are about the side, top or bottom surfaces of said plug.
7. The plug, as recited in claim 6, wherein said protuberances are ridges.
8. The plug, as recited in claim 7, wherein said protuberances are aligned perpendicular to the axial direction of the plug or parallel to the axial direction of the plug.
9. The plug, as recited in claim 8, wherein said ridges form a series of rings about the circumferential surface of said plug.
10. The plug, as recited in claim 9, wherein said protuberances are distinctly separate from each other.
11. The plug, as recited in claim 10, wherein said protuberances blend into adjacent said protuberances.
12. The plug, as recited in claim 1, further comprising said plug being a plug tapered to approximately 1 degree of taper.
13. The plug, as recited in claim 1, further comprising said plug being a wooden plug.
14. The plug, as recited in claim 13, wherein said plug is tapered to approximately 1 degree of taper.
15. The plug, as recited in claim 14, wherein said plug is made of a manufactured material.
16. The plug, as recited in claim 1, further comprising said elements being elements incised into said plug.
17. The plug, as recited in claim 1, further comprising having a round, straight sided, or tapered form.
18. The plug, as recited in claim 1, further comprising having an installation time of less than 30 seconds.
19. A plug, comprising: a plug having a dimensional tolerance of about +/33 percent of its specified size, said plug tapered to approximately one degree, said plug having a three-dimensionally textured surface made up of elements generated upon said plug, said elements causing said plug to exert a strong hold-in force of outwardly directed pressure against a side wall of a drilled hole into which the plug is installed causing said plugs, when used to plug holes, to successfully plug holes miss-drilled to have diameter sizes that vary up to thirty-three percent smaller or larger from the specified hole/plug size.
20. A plug, comprising: a wood plug with dimensional tolerance of about +/33 percent of its specified size, said plug tapered to approximately one degree, said plug having a three-dimensionally textured surface made up of elements imparted upon said plug, said elements causing said plug to exhibit a strong hold-in force of outwardly directed pressure against a side wall of a drilled hole into which the plug is installed causing said plugs, when used to plug holes, to successfully plug holes miss-drilled to have diameter sizes that vary up to thirty-three percent smaller or larger from the specified hole/plug size, said plug not requiring the addition of a glue, special tools, or special fasteners in its installation.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] In order that these and other objects, features, and advantages of the present invention may be more fully comprehended and appreciated, the invention will now be described, by way of example, with reference to specific embodiments thereof which are illustrated in appended drawings wherein like reference characters indicate like parts throughout the several figures. It should be understood that these drawings only depict preferred embodiments of the present invention and are not therefore to be considered limiting in scope, thus, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which:
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A LIST OF REFERENCE NUMBERS AND THE PARTS TO WHICH THEY REFER
[0022] 2 Top surface of plug 10. [0023] 4 Side surface of plug 10. [0024] 6 A series of concentric ridged rings projecting from the plug wall 4. [0025] 8 A series of concentric recessed rings in plug wall 4. [0026] 10 An example of a plug. [0027] 12 Largest diameter ridged ring. [0028] 14 A screw. [0029] 16 A floorboard. [0030] 18 A joist. [0031] 20 A recess. [0032] 22 Wood face grain on top surface of plug. [0033] 24 Incised three-dimensional elements on side of plug.
DEFINITION
[0034] Concentric objects, as used herein, refer to a set of objects that each share the same center, axis, or origin, but are sized so that each object in the series has a radius larger or smaller than the object adjacent to it. An example of a concentric series of inscribed rings, for example, would be the rings inscribed into the outer side surface of a plug, where the diameter of the plug, and, thus, the diameter of the inscribed rings, decreases from the top to the bottom of the plug. [0035] Dimensional tolerance of an absorbing or accepting structured plug, as used herein, refers to the plug's ability to accommodate the differences that can occur in the size and shape of a hole into which a plug is to be inserted during the hole-drilling process. The structure of such a structured plug provides a strong hold-in force or outwardly directed pressure against the side wall of the drilled hole into which the plug is placed to hold-in the plug. This hold-in force maintains the plug in the holes when glue is, or is not, used even if the holes are drilled to have diameters that are about thirty-three percent smaller or larger than the plug specified for a given set of holes because of the built-in dimensional tolerance of about +/33 percent of the plugs of the present invention. Another way of describing this dimensional tolerance is that the hold-in force maintains the plug in the holes even if the drilled hole has a diameter about thirty-three percent greater or smaller than the diameter of plugs being used to fill the holes. [0036] Textured surface, as used herein, refers the principles of the inventive concept that require that the surface of each plug is textured, that is each plug is manufactured to have a deliberately formed, unsmooth surface by imparting a structure of related elements upon a surface of the plug. The structure of related elements generally forms a texture pattern on the surface, but it should be understood that the pattern may be regular or irregular. [0037] Tolerance or Dimensional tolerance, as used herein, refers to the permissible range of variation in the dimension of an object. The accepted permissible range of variation in the dimension of an object depends on the material from which that object is made.
[0038] It should be understood that the drawings are not necessarily to scale. In certain instances, details which are not necessary for an understanding of the present invention or which render other details difficult to perceive may have been omitted.
DETAILED DESCRIPTION
[0039] Referring now, with more particularity, to the drawings, it should be noted that the disclosed invention is disposed to embodiments in various sizes, shapes, and forms, as are described above and below or shown in the drawings. Therefore, the embodiments described herein are provided with the understanding that the present disclosure is intended as illustrative and is not intended to limit the invention to the embodiments described.
[0040] As stated above, installers are familiar with the inconveniences posed by the commonly available wooden plugs that are used to fill the imperfectly sized and shaped holes drilled for the insertion of screws into boards that are to be attached to their support joists. After considerable study of all of the variables that can be present during the plugging operation, such as the shape and size of plugs, the shape, size, and orientation of the hole that is drilled to receive the attaching screw or nail and the plugs, and the method and means used to drill the hole, the present Inventor identified several reasons for the problems. Relying on his analysis of these variables, the Inventor, from his inventive concept, developed a set of principles that, when followed, make plugs for filling imperfectly sized and shaped holes. Thus, the plugs, as taught herein, either eliminate the identified problems or compensate for the problems. The inventive concept provides the principles for making plugs that have a high degree of dimensional tolerance. In fact, the plugs have a +/ tolerance of about 33 percent. When plugs made following the principles of the present invention are used to fill-in imperfectly drilled screw holes, each plug is able to exert a strong hold-in force of outwardly directed pressure, regardless of the fact that the hole may be miss-happen or miss-sized. In fact, the plugs of the present invention can successfully plug imperfectly drilled holes that have diameters that range between about 33 % greater or smaller than the diameter of the specified drilled hole. The exact percentage of this tolerance, of course, changes a small amount depending on the material used to make the plug. This dimensional tolerance difference between materials is well understood in the art. The outwardly directed pressure exerts force against the side wall of the drilled hole into which the plug is placed to maintain the plug in the hole even when glue is not used. The hold-in force is provided by manufacturing each plug to be tolerance accepting. That is, the principles of the inventive concept of the present invention require a three-dimensional texture comprising a structure of related elements to be imparted to a surface of each plug. That is, each plug is adapted to have either outwardly projecting protuberances about a surface, which is most often, the circumferential side surface of the plug or incisions or indentations on that surface. It is to be understood that although the textured surface is the side surface of a plug, there are instances where to top or bottom surface are also treated to having a texture. That is each plug has a deliberately manufactured, non-smooth textured surface that is caused by imparting a structure of related elements upon one or more of its surfaces. It is the texture imparted to each plug that provides the tolerance acceptance. If the hole into which the plug is inserted is larger than specified, the texture forming elements of the plug expand to fill the space. If the hole into which the plug is inserted is smaller than specified, the elements have the space provided by recesses between elements to collapse. Elements that are protuberances may take a variety of shapes and designs and include rings, ridges, and nodes, for example. The orientation of the ridges can be circumferential, that is aligned perpendicular to the axial direction of the plug, aligned parallel to the axial direction of the plug, or have a wave form, for example. The protuberances comprise continuous ringed ridges about the side of the plug or are individual knobs, bulges, or nodes, or a combination thereof. The ridges or incisions may be spaced with relative regularity or irregularity with regard to one another. The ridges or incisions may cross each other. The plugs are produced in required forms, such as having their peripheries be round, oval, square, rectangular, or irregular with side surfaces that can be straight or tapered, keeping in mind that the tapering should be kept to a minimum. If needed, plugs of this invention may be angled to various degrees. One example, is besides the more typical round plug, some plugs may have a winged, shape or may be angled to conform to a particular shape of a hole. Some special needs include plugs with protuberances or incisions on only an isolated area of a plug. Plugs, made according to the principles of the present invention, may be tapered, but when used in straight-sided holes the taper is always kept to a minimum to avoid having the plug leave a gap, that may be fill with water and be a cause of rot to the material in which the plug is positioned. It is preferred that plugs meant for use in straight-sided holes, the taper is kept close to one degree of taper.
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[0047] According to the principles of the present invention, the plugs may be manufactured from any material that will satisfy the requirements of the job. Some jobs might require that the presence of the plugs is as invisible as possible. In that case, the plugs are likely to be made from the same material as the surface into which they are being installed, such as a flooring surface. Alternatively, for example, when there is a need for some boards in a floor to be replaced and the replaced boards are not exactly the same as the boards that do not need to be replaced plugs of a different color, shade, or texture would create a diversion and take the eye away from the mismatched boards. In some instances, the plugs may be designed to contrast with the surface into which they are being installed, to be used as a visual distraction, away from imperfections in the floor, for example.
[0048] It is to be understood that the plugs of the present invention have many intended uses, such as filling in holes drilled in floors, walls, ceilings, railings, stairs, furniture, or any place where a plug is required or desired. In some uses, the average diameter size of drilled holes intentionally vary. In that case, the average size of the plug made according to the principles of the present invention may also vary. Most commonly available plugs made for filling holes drilled into deck-floorings range in diameter from about (0.375) in the United States and 10 mm (0.394) in Europe. Some are a little smaller at (0.25) and some are a little bigger like (0.50). The diameter size of the plugs of the present invention ranges from about (0.125) diameter to 1 (1.5) with each diameter size being able to successfully plug an imperfectly sized drilled hole having a diameter tolerance that can range between about 33% greater or smaller than the diameter of a perfectly drilled hole of a specified size. It is well-accepted that the accepted permissible range of variation, i.e., dimensional tolerance, in the dimension of an object depends on the material from which that object is made and the accepted range of tolerance for a given material is well-documented.
[0049] The plugs of the present invention are easy to use. First a hole is drilled into the board to be attached to its support studs. No special tools are required. Any drill commonly used for this purpose is acceptable. A screw or other fastener is then installed through the hole just drilled to anchor the board to its support. Once the fastener is in place, if using glue, a small amount is squirted into the hole. A plug is then positioned over and partially into the hole and hammered in. That usually finishes the job. Using the plugs of the present invention, it should take no longer than 20 seconds to drill a hole, apply glue if desired, and install the plug and be ready to go on to the next hole. Most times, the plug will fit into the hole and be co-planar with the surface into which it was installed. If the surface of a plug is not in perfect alignment with the surface of the board, a quick sanding will have the surface of the plug and the surface of the board in perfect matched alignment.
[0050] This is very different from other systems where the fastener must have two different sets of threads, a head with it periphery and underside specially configured, and must be installed to a predetermined depth. The plugs to be used with this system must be dimensioned for a given fastener and must meet several specific dimensions for use with prescribed drivers and must fit the width and depth of the hole exactly so that the surface of the plug and the board into which it is being installed are coplanar by mere insertion, which causes issues because of the tolerance associated with drilling the depth of a hole to an exact dimension causing the plug to either sit too highcausing a tripping hazard when installed on a floor or be aesthetically unpleasing. Moreover, the use of glue is suggested to maintain the plug in place. To limit the penetration depth of the fastener, the body of the driver requires a spring loaded washer to be mounted to it. In fact, in some systems, the counterbore (the part of the hole into which the plug is to be installed, is required to be slightly smaller than the fastener head. These other systems are complicated, require accurately measured installations, fasteners, and tools which means that they require time and expense. Some systems require that the plugs be made of the same material into which they are to be installed. Some plugs are expressly conically tapered so that there will be an annular cavity remaining once the plug is in place. This seems to make an unstable system one where the plug could easily become tilted which means that the outer face of the plug would lose co-planarity with the board. Others require a stepped plug with a wide part and a narrow part made to exact dimensions to coordinate with the fastener used; the height of each part must be of exact dimension also to fit with the predetermined depth to which the fastener is installed. To assure that a fastener is driven to the predetermined depth a stopper must be used to limit the rotation of the drill once the predetermined depth is reached. The plugs must be specially configured. Other systems require compression grooves that are incised deeply into the body of the plug and require the use of glue. Some special use plugs are made out of highly resilient material and to have hollow interiors that can be used to hold special materials, such as termite insecticide. Other specialty plugs are designed to have unique shapes for use in holes that have accepting shapes. These kinds of plugs are too different in structure and function to be compared to the plugs of the present invention.
[0051] The system and method of the present invention provides for rapid and easy installation where the entire installation can be complete in significantly less than 30 seconds. The cost of the plugs meets the needs of jobs where thousands of plugs are used. The plugs of the present invention that are used in floor and deck installations are required to be made without caps and surface decorations. The plugs of the present invention may of course be used with equal ease and pleasing results in installations that are other than floor. Glue may be used if desired, but is not required. There is no additional time or financial investment required as no special tools required, such as are required for other systems. The plugs are not required to be specifically configured, neither do the plugs of this invention have to be made to exact dimensions and need not exactly fit the width and depth of the hole into which they are to be installed. If the plugs are seated too high a quick sanding brings them into planarity with the board into which they are inserted. The plugs of the present invention do not need to be expressly conically tapered and do not have to have an annular cavity remaining once the plug is in place, nor do the plugs of the present invention require the plug be stepped with a wide part and a narrow part each made to exact dimensions to coordinate with the fastener used. The fastener is not required to have two different sets of threads and need not be installed to a predetermined depth and any driver and any drill suitable for the purpose will work. The driver used does not require either a spring or a stop to control the depth of the fastener as it is being driven through the board into the board's support. The plugs of the present invention do not require prescribed deck screws and drivers, and the counterbore is not required to be smaller than the head of the fastener. The present invention relies on the plugs having manufactured three-dimensional textural elements on the outside surfaces of the plugs to provide the plugs with their hold-in force of outwardly directed pressure and do not require or use compression grooves that are incised deeply into the body of the plug.
[0052] The foregoing description, for purposes of explanation, uses specific and defined nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that the specific details are not required in order to practice the invention. Thus, the foregoing description of the specific embodiment is presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed. Those skilled in the art will recognize that many changes may be made to the features, embodiments, and methods of making the embodiments of the invention described herein without departing from the spirit and scope of the invention. Furthermore, the present invention is not limited to the described methods, embodiments, features or combinations of features but include all the variation, methods, modifications, and combinations of features within the scope of the appended claims. The invention is limited only by the claims.