CA2593856A1 - Wall covering panel cutting template - Google Patents

Abstract

A template for permitting the accurate hole cutting in a wall covering panel for mounting around an electrical utility box comprises a main body having a cutting tool guide aperture. The cutting tool guide aperture has a predetermined shape according to the shape and size of the electrical utility box, for temporary fitment of the template in surrounding relation around the electrical utility box mounted on the structural frame. Threaded fasteners are used to temporarily attach the main body to the wall covering panel when the wall covering panel is forced onto the template. The threaded fasteners remain in the wall covering panel when the template is removed from the electrical utility box and structural frame. The main body provides an outer perimeter for guiding a cutting tool and limiting the cutting area available to the cutting tool, for accurately and quickly cutting the hole in the wall covering panel.

Description

FIELD OF THE INVENTION

[0001] This invention relates to templates for use in cutting holes in wall covering panels to be mounted on a wall frame, and more particularly to such templates that permit the accurate cutting of a hole in a wall covering panel for subsequent mounting on a wall frame around an electrical utility box.

BACKGROUND OF THE INVENTION

[0002] When mounting a wall covering panel, such as a piece of wallboard, which is often known as drywall, or other types of wall covering panels, onto a wall frame or a ceiling frame comprising a plurality of spaced apart supporting studs, it is often necessary to mount the wall covering panel onto a section of the wall frame or ceiling frame where there is an electrical utility box, such as an electrical outlet, light switch, light fixture, or the like. It is often necessary to cut a hole in the wall covering panel for receiving therein the front portion of the electrical utility box that is mounted on one of the studs of the wall frame or ceiling frame. This hole must be cut quite accurately as there is little room for error. The cover plate that is mounted onto the electrical utility box, or the like, covers only about one centimeter beyond the area of the electrical utility box.
Otherwise, the hole will be visible when the wall covering panel is in place and the cover plate, or the like, is in place on the electrical utility box. Accordingly, the wall covering panel would have to be either repaired or even discarded if major alignment mistakes are made.

[0003] Present methods of installing around a wall covering panel include measuring the location of the electrical utility box with respect to both a vertical and horizontal reference, and marking the wall covering panel with these measurements. While this method does work well in theory, its success depends on the skill and experience of the installer of the wall covering panel.
It is well known that it tends to lead to an unacceptable number of mistakes and extra installation time.

[0004] Other methods exist for marking the placement of a hole in a wall covering panel to receive an electrical utility box therein, including using a pencil or suitable marker to mark the front perimeter edge of the electrical utility box on the back of the wall covering panel. The wall covering panel is then temporarily put in place at the wall frame or ceiling frame over the electrical utility box. The pencil lead or ink, as the case may be, that is on the front perimeter edge of the electrical utility box, is transferred in part to the wall covering panel.
The wall covering panel is then cut at the transferred marking.
This method is still prone to inaccuracies and mis-cutting, especially for inexperienced individuals. One particular problem with this method is that typically the electrical utility box is mounted so as to be angled slightly such that its front face is somewhat askew to the face of the wall frame or ceiling frame.
Accordingly, the pencil lead or ink is only partially transferred, and a portion of the outline of the electrical utility box must be guessed at when cutting the hole.

[0005] A similar method that works only with a readily deformable type of wall covering panel, such as drywall, is to merely place the wall covering panel at the wall frame or ceiling frame against the electrical utility box, and then sharply pound the wall covering panel against the utility box. This method causes a physical outline of the electrical utility box to be impressed, either fully or partly, into the back face of'the wall covering panel. Again, this method is prone to inaccuracies and mis-cutting, especially for inexperienced individuals. Further, damage is common using this method.

[0006] United States Patent No. 6,403,883, issued June 11, 2002 to Morgan et al, discloses a Combination Protective Covering Insert and Locator for an Electrical Utility Box Utilized in a Wall Covering Application. This locator is for use with an electrical utility box during an application of a wall covering material over a structural frame to which the insert is secured. The insert is constructed as a three dimensional housing with a forward facing and peripherally extending planar face and a rearwardly spaced and recessed base surface, connected together by side walls. The side walls in combination define a mating configuration with the peripherally extending edge of the utility box. A spike is secured to a midpoint location of the recessed base surface and extends forwardly a predetermined spaced distance beyond the peripherally extending planar face. The spike pierces through a specified location of the wall covering material during application over the matingly engaged insert and identifies a midpoint location of the utility box for subsequent removal of the wallboard overlying the utility box. While this locator does work, it does not solve the problems of inaccuracies and mis-cutting. In use, a cutting saw cuts around the outer perimeter of the locator. Since the saw is cutting exteriorly to the locator, a saw can easily cut the wall board well beyond the outer perimeter of the locator, thus requiring the wallboard to be fixed or even discarded. Further, it cannot properly be used if the electrical utility box has an electrical fixture installed in it.

[0007] It is an object of the present invention to provide a template that permits accurate cutting out of a portion of a wall covering panel that is to be mounted on a wall frame at an electrical utility box.

[0008] It is another object of the present invention to provide a template that permits accurate cutting out of a portion of a wall covering panel that is to be mounted on a wall frame at an electrical utility box, which template precludes mis-cutting of the hole.

[0009] It is a further object of the present invention to provide a template that permits accurate cutting out of a portion of a wall covering panel that is to be mounted on a wall frame at an electrical utility box, which template is quick and easy to use.

[00010] It is a further object of the present invention to provide a template that permits accurate cutting out of a portion of a wall covering panel that is to be mounted on a wall frame at an electrical utility box, which template precludes wasting of material.

[00011] It is a further object of the present invention to provide a template that permits accurate cutting out of a portion of a wall covering panel that is to be mounted on a wall frame at an electrical utility box, which template can be used in conjunction with an electrical utility box having an electrical fixture installed therein.

SUbIlKARY OF THE INVENTION

[00012] In accordance with one aspect of the present invention there is disclosed a novel template for permitting the accurate cutting of a hole in a wall covering panel for subsequent mounting on a structural frame around an electrical utility box. The template comprises a main body and a cutting tool guide aperture disposed in the main body. The cutting tool guide aperture has a predetermined shape according to the shape and size of the electrical utility box, for temporary fitment of the template in surrounding relation around the electrical utility box mounted in the structural frame. There is an attachment means for temporarily attaching the main body to the wall covering panel when the wall covering panel is forced into the template, such that the attachment means remains in the wall covering panel when the template is removed from the electrical utility box and structural frame. The main body provides an outer perimeter for guiding a cutting tool and limiting the cutting area available to the cutting tool, for accurately cutting the hole in the wall covering panel.

[00013] In accordance with another aspect of the present invention there is disclosed a novel method of accurately cutting of a hole in a wall covering panel for subsequent mounting on a structural frame around an electrical utility box. The method comprises the steps of temporarily mounting a template having a cutting tool guide aperture, in surrounding relation surrounding relation the electrical utility box mounted in a structural frame;
placing a wall covering panel on the template such that the main body of the template is temporarily attached to the wall covering panel; and accurately cutting a hole in a wall covering panel, the hole being in the shape of the cutting tool guide aperture; and removing the template from the wall covering panel.

[00014] Other advantages, features and characteristics of the present invention, as well as methods of operation and functions of the related elements of the structure, and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following detailed description and the appended claims with reference to the accompanying drawings, the latter of which is briefly described herein below.

BRIEF DESCRIPTION OF THE DRAWINGS

[00015] The novel features which are believed to be characteristic of the template according to the present invention, as to its structure, organization, use and method of operation, together with further objectives and advantages thereof, will be better understood from the following drawings in which a presently preferred embodiment of the invention will now be illustrated by way of example. It is expressly understood, however, that the drawings are for the purpose of illustration and description only, and are not intended as a definition of the limits of the invention. In the accompanying drawings:

[00016] Figure 1 is a perspective view from the front of the first preferred embodiment of the template according to the present invention;

[00017] Figure 2 is a front elevational view of the first preferred embodiment of the template of Figure 1;

[00018] Figure 3 is a rear elevational view of the first preferred embodiment of the template of Figure 1;

[00019] Figure 4 is a top plan view of the first preferred embodiment of the template of Figure 1;

[00020] Figure 5 is a bottom plan view of the first preferred embodiment of the template of Figure 1;

[00021] Figure 6 is a side elevational view of the first preferred embodiment of the template of Figure 1;

[00022] Figure 7 is a perspective view from the front of an electrical utility box mounted on a stud of a wall frame;

[00023] Figure 8 is a perspective view from the front of the first preferred embodiment of the template of Figure 1, in place on the electrical utility box of Figure 7 mounted on a stud of a wall frame;

[00024] Figure 9 is a perspective view from the rear of the first preferred embodiment of the template of Figure 7, in place on the electrical utility box mounted on a stud of a wall frame;

[00025] Figure 10 is a perspective view from the rear similar to Figure 9, but with a wall covering panel in place on the template;

[00026] Figure 11 is a top plan view of the wall covering panel in place on the first preferred embodiment template in place on the template, as in Figure 10;

[00027] Figure 12 is a perspective view from the rear of the wall covering panel and first preferred embodiment template having been removed from the wall frame and electrical utility box;

[00028] Figure 13 is a rear elevational view of the wall covering panel and first preferred embodiment cutting template in place on the wall covering panel;

[00029] Figure 14 is a perspective view from the rear o the wall covering panel and first preferred embodiment cutting template in place on the wall covering panel, and also showing a hole being cut in the wall covering panel by a cutting tool;

[00030] Figure 15 is a perspective view from the rear similar to Figure 14, but with the template removed and showing the accurately cut hole in the wall covering panel;

[00031] Figure 16 is a front elevational view of the first preferred embodiment of the template of Figure 1, but in a'folded closed storage configuration;

[00032] Figure 17 is a side elevational view of the first preferred embodiment of the template of Figure 1, but in a folded closed storage configuration;

[00033] Figure 18 is a side elevational view of the first preferred embodiment of the template of Figure 1, but part way between a folded closed storage configuration and an open in-use configuration;

[00034] Figure 19 is a front elevational view of the second preferred embodiment of the template according to the present invention; and [00035] Figure 20 is a perspective view from the front of the third preferred embodiment of the template according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[00036] Referring to Figures 1 through 20 of the drawings, it will be noted that Figures 1 through 18 illustrate a first preferred embodiment of the template of the present invention, Figure 19 illustrates a second preferred embodiment of the template of the present invention, and Figure 20 illustrates a third preferred embodiment of the template of the present invention.

[00037] Reference will now be made to Figures 1 through 18, which show a first preferred embodiment of the template of the present invention, as indicated by general reference numeral 20. The first preferred embodiment template 20 is for permitting the accurate cutting of a hole 22 in a wall covering panel 24, "Such as wallboard, the most common type of which is know as drywall, for subsequent mounting on a structural frame 26 of a wall or ceiling around an electrical utility box 29, such as an electrical outlet, a light switch, a light socket, and so on. The wall covering panel 24 might also be a piece of wood paneling, or the like.

[00038] The structural frame 26 typically consists of a plurality of parallel spaced apart wood or metal studs. Typically, the electrical utility boxes 29 are industry standard electrical utility boxes 29, and are of a predetermined size and shape. For instance, a standard single electrical utility box might house a single light switch or a pair of electrical receptacles. A double electrical utility box might house two electrical switches, for instance.

[00039] The first preferred embodiment template 20 comprises a main body 30 that is preferably made of unitary construction from a suitable plastic material, thus allowing the template 20 to be mass produced at a low cost.

[00040] As can be readily seen in the Figures, and as perhaps best seen in Figure 17, the main body 30 comprises a first body portion 32 and a second body portion 34. The main body 30 is foldable about a fold axis "F" between an open in-use configuration, as is best seen in Figures 1 to 15, and a folded closed storage configuration, as is best seen in Figures 16 and 17.
In the open in-use configuration, the first body portion 32 and the second body portion 34 are substantially co-planar. In the folded closed storage configuration, the first body portion 32 and the second body portion 34 face one another for the purposes of safe handling and compact storage, as will discussed in greater detail subsequently. It should be noted that a magnet and co-operating ferrous metal piece could be used to keep the first body portion 32 and the second body portion 34 against each other in the closed storage configuration, and also in the open in-use configuration.

[00041] The first body portion 32 and the second body portion 34 are interconnected one to the other by a hinge means 60. In the first preferred embodiment as illustrated, the hinge means 60 comprises a flexible plastic hinge 60, often referred to as a "living hinge", which is integrally molded with the first body portion 32 and the second body portion 34. Forming the main body 30 in this manner is cost effective in that separate hinges do not need to be mounted to the main body 30 during the manufacturing process. Alternatively, a conventional hinge could also be used.

[00042] A cutting tool guide aperture 40 is disposed within the main body 30, such that the main body 30 completely surrounds the cutting tool guide aperture 40. The cutting tool guide aperture 40 has a predetermined shape according to the shape and size of the electrical utility box 29. In the first preferred embodiment, as illustrated, the cutting tool guide aperture 40 is slightly larger, typically by a couple of millimeters or so, than the size of a conventional industry standard single electrical utility box. The cutting tool guide aperture 40 permits temporary fitment of the template 20 in surrounding relation around the electrical utility box 29 mounted on the structural frame 26, as can be best seen in Figures 7 through 11.

[00043] The present invention also comprises an attachment means 50 for temporarily attaching the main body 30 to the wall covering panel 24, when the wall covering panel 24 is forced onto the template 20, with the template 20 being in surrounding relation around the electrical utility box 29 mounted on the structural frame 26, such that the attachment means 50 remains in the wall covering panel 24 when the template 20 is removed from the electrical utility box 29 and the structural frame 26.

[00044] The attachment means 50 comprises at least one spike means 50, and preferably comprises a plurality of spike means 50.
In the first preferred embodiment, as illustrated, each of the at least one spike means 50 comprises an elongate body and a thread on the elongate body, and is preferably a threaded fastener 50. Most preferably, the threaded fastener 50 comprises a drywall screw 50 that is removably and replaceably mounted in the main body 30, such that the threads of the drywall screw 50 threadibly engage the plastic material of the main body 30. In this manner, the drywall screws 50 can be adjusted to a desired axial position such that they project outwardly from the main body 30 by a desired distance, in order to penetrate into the wall covering panel 24, but not extend through to the front face of the wall covering panel, as is best seen in Figure 11.

[00045] As can be readily seen in the Figures, at least one of the plurality of spike means 50 is disposed on the first body portion 32 of the main body 30, and at least one of the plurality of spike means 50 is disposed on the second body portion 34. More specifically, two of the threaded fasteners 50 are mounted within cooperating receiving apertures within the first body portion 32, and two threaded fasteners 50 are mounted within cooperating receiving apertures in the second body portion 34.

[00046] Further, the main body 30 includes a plurality of spike-receiving holes 52, one spike-receiving hole 52 for each spike means 50. Accordingly, there are four spike receiving holes 52 in the main body 30 portion with two spike receiving holes 52 being disposed in the first body portion 32 and two spike receiving holes 52 being disposed in the second body portion 34. The first spike receiving hole 52a receives the first threaded fastener 50a therein; the second spike receiving hole 52b receives the second threaded fastener 52b therein; the third spike receiving hole 52c receives the third threaded fastener 50c therein; and the fourth spike receiving hole 52d receives the fourth threaded fastener 50d therein, as can be best seen in Figure 16.

[00047] The various threaded fasteners 50 are longitudinally offset one from another, with respect to the fold axis "F", so that they will not interfere with each other when the main body 30 is in its folded closed storage configuration. As can be readily seen, the main body 30 of the template 20 according to the present invention provides an outer perimeter for guiding a cutting tool, such as a saw 70, as can be seen in Figure 14, and limiting the cutting area available to the saw 70, for accurately cutting the hole 22 in the wall covering panel 24.

[00048] The present invention also comprises a method of accurately cutting a hole 22 in a wall covering panel, for subsequent mounting on a structural frame 26 around an electrical utility box 29. The method comprises the steps of temporarily mounting a template 20 having a cutting tool guide aperture 40 in surrounding relation around the electrical utility box 29 mounted on the structural frame 26, as indicated by arrow "A" in Figure 7, and as shown fully mounted in Figures 8 and 9. The next step is to place a wall covering panel 24 on the template 20, such that the main body 30 of the template 20 is temporarily attached to the wall covering panel 24, as is shown in Figures 10 and 11. In this step, the spike means 50, specifically the threaded fasteners 50, penetrate into the wall covering panel 24, but do not penetrate through the front face of the wall covering panel 24, so as not to damage the front face, which would be seen after the wall covering panel 24 is fully mounted on the structural frame 26. The next step is to accurately cut a hole 22 in the wall covering panel 24, using an appropriate tool, such as a saw 70, or other suitable cutting tool, as can be best seen in Figure 14. Finally, once the hole 22 has been accurately cut into the wall covering panel 24, the template 20 can be removed therefrom, by simply pulling on the template 20, in the direction indicated by arrow "B" in Figure 15.

[00049] Figures 16 and 17 show the template 20 separately in its folded closed storage configuration which enables easy and safe carrying and storage of the template 20. As can be seen in Figures 16 and 17, the flexible hinge 60 bends one-hundred eighty degrees when the template 20 is in its folded closed storage configuration.

[00050] As shown in Figure 18, the template 20 is moved from its open in-use configuration to its folded closed configuration in a direction indicated by arrow "C", and is moved from its folded closed configuration to its open in-use configuration in a direction indicated by arrow "D".

[00051] Reference will now be made to Figure 19, which shows a second preferred embodiment of the template of the present invention, as indicated by general reference numeral 220. The template 220 is similar to the first preferred embodiment template 20, except that the cutting tool guide aperture 240 in the template 220 is shaped and dimensioned for a double size electrical utility box. Also, the first body portion 232 and the second body portion 234 are separated vertically instead of horizontally. Further, the spike means, specifically the drywall screws 250, are laterally offset one from another with respect to the fold axis "L".

[00052] Reference will now be made to Figure 20, which shows a third preferred embodiment of the template of the present invention, as indicated by general reference numeral 320. The template 320 is similar to the first preferred embodiment template 20, except that the main body 330 is of unitary construction without having a first body portion and a second body portion.

[00053] As can be understood from the above description and from the accompanying drawings, the present invention provides a template that permits accurate cutting out of a portion of a wall covering panel that is to be mounted on a wall frame at an electrical utility box, which template precludes mis-cutting of the hole, which template is quick and easy to use, which template precludes wasting of material, and which template can be used if the electrical utility box has an electrical fixture installed in it, all of which features are unknown in the prior art.

[00054] Other variations of the above principles will be apparent to those who are knowledgeable in the field of the invention, and such variations are considered to be within the scope of the present invention. Further, other modifications and alterations may be used in the design and manufacture of the template of the present invention without departing from the spirit and scope of the accompanying claims.

Claims (19)

1. A template for permitting the accurate cutting of a hole in a wall covering panel for subsequent mounting on a structural frame around an electrical utility box, said template comprising:
a main body;

a cutting tool guide aperture disposed in said main body, said cutting tool guide aperture having a predetermined shape according to the shape and size of the electrical utility box, for temporary fitment of said template in surrounding relation around the electrical utility box mounted on the structural frame; and, attachment means for temporarily attaching said main body to the wall covering panel when said wall covering panel is forced into said template, such that said attachment means remains in said wall covering panel when said template is removed from said electrical utility box and said structural frame;

wherein said main body provides an outer perimeter for guiding a cutting tool and limiting the cutting area available to the cutting tool, for accurately cutting said hole in the wall covering panel.

2. The template of claim 1, wherein said attachment means comprises at least one spike means.

3. The template of claim 2, wherein each of said at least one spike means comprises an elongate body and a thread on said elongate body.

4. The template of claim 3, wherein each of said at least one spike means comprises a threaded fastener.

5. The template of claim 4, wherein each said threaded fastener comprises a drywall screw.

6. The template of claim 5, wherein each said drywall screw is removably and replaceably mounted in said main body.

7. The template of claim 1, wherein said main body completely surrounds said cutting tool guide aperture.

8. The template of claim 1, wherein said main body is made from a plastic material.

9. The template of claim 8, wherein said main body comprises a first body portion and a second body portion.

10. The template of claim 9, wherein said main body is foldable about a fold axis between an open in-use configuration whereat said first body portion and said second body portion are substantially co-planar, and a folded closed storage configuration, whereat said first body portion and said second body portion face one another.

11. The template of claim 10, wherein said attachment means comprises a plurality of spike means.

12. The template of claim 11, wherein at least one of said plurality of spike means is disposed on said first body portion and at least one of said plurality of spike means is disposed on said second body portion.

13. The template of claim 12, wherein said spike means are longitudinally offset one from another along said fold axis.

14. The template of claim 12, wherein said spike means are laterally offset one from another with respect to said fold axis.

15. The template of claim 12, wherein said main body includes a plurality of spike-receiving holes, one spike receiving hole for each spike means.

16. The template of claim 10, wherein said first body portion and said second body portion are interconnected one to the other by a hinge means.

17. The template of claim 16, wherein said hinge means comprises a flexible plastic hinge integrally moulded with said first body portion and said second body portion.

18. The template of claim 1, wherein said main body is of a unitary construction.

19. A method of accurately cutting of a hole in a wall covering panel for subsequent mounting on a structural frame around an electrical utility box, said method comprising the steps of:

temporarily mounting a template having a cutting tool guide aperture, in surrounding relation around the electrical utility box mounted on the structural frame;

placing a wall covering panel on said template such that said main body of said template is temporarily attached to the wall covering panel;

accurately cutting a hole in the wall covering panel, said hole being in the shape of said cutting tool guide aperture;
and, removing said template from said wall covering panel.