GB2452529A

GB2452529A - Jig for alignment of two adjacent sheets

Info

Publication number: GB2452529A
Application number: GB0717362A
Authority: GB
Inventors: John Oswin Metcalf
Original assignee: Individual
Current assignee: Individual
Priority date: 2007-09-06
Filing date: 2007-09-06
Publication date: 2009-03-11
Also published as: GB0717362D0; GB2452586A; GB0809280D0

Abstract

A jig 10 is disclosed for assisting with the alignment of corresponding surfaces of two adjacent sheets 44, 46, and in particular to a device for assisting with the level alignment of two abutting worktops, for example when fitting a kitchen worktop. The jig comprises a first portion 38 having a first surface for securing directly to the first sheet, and a second portion 18, not overlying the first portion, having a second surface that in use will face the second sheet. An adjustment device, such as a bolt 28, is provided for contacting the second sheet, which allows adjustment of the relative positions of the first and second sheets. The adjustment device can be adjusted at a third surface of the jig and comprises a screw thread, the first and second portions being in fixed positions relative to each other and the second surface being stepped down from the first.

Description

V

Surface Leveller This invention relates to a device for assisting with the alignment of corresponding surfaces of two adjacent sheets, and in particular to a device for assisting with the level alignment of two abutting worktops, for example when fitting a kitchen worktop.

There are many applications in the building industry where two or more sheets want to be fitted together with a flush surface finish. Examples include walls, ceilings, floors and worktops and the sheets may be plasterboard sheets, solid wood sheets (e.g. for panelling or for solid wood flooring), plywood sheets and wood, marble, resin or laminate worktops. The present invention relates to all of those applications. However, for simplicity, the remaining disclosure will relate to the fitting of kitchen worktops.

Worktop sheets are usually supplied in sheets of fixed dimensions. For example, kitchen worktops are usually sold in standard lengths of 3 or 4 meters, and with a standard width, e.g. 600,620 or 650mm.

Given those fixed sizes, it is rare that such a sheet will be the correct size for the given application. Thus it is common practice to have to cut the fixed size sheets into one or more piece of a more appropriate size and shape and then to join together that piece with one or more other pieces so as to form the desired shape or size for the finished worktop.

That is usually done in situ.

Such a piecing together of pieces of worktop is particularly necessary where the required worktop turns a corner or where it is longer or wider than the standard sheet, such as in galley style kitchens, or in kitchens having either a peninsula or an island (i.e. where two sheets usually get joined together side by side, rather than end to end, so as to provide the peninsula or island with two finished edges).

The forming of a perfect surface finish for those joints, however, is far from easy due to the stiffness and weight of the sheets, and due to the probable non-flatness of the underlying substrate. Further, it can be made even more difficult where the two sheets to be joined have different thicknesses -worktop sheets can come in a variety of different thicknesses. For example, kitchen worktops are often any of 27, 38, 40 or 60mm thick, and adjacent worktops are not necessarily of the same thickness. For example, a wooden worktop of one thickness might be joined to a laminate worktop of a different thickeness.

Despite these difficulties, however, kitchen fitters generally strive to provide a perfect surface finish for the worktop, i.e. with no ridge or step between the adjacent sheets at the joint. To achieve that, smooth (straight, curved or J shaped) edges are formed on the two faces of the two pieces for abutting together, such as with a router and a router jig, whereby the two pieces will accurately and cleanly marry together. Recesses are also cut into the undersides of the two worktop pieces (also with the router) for allowing special longitudinal 1-clamps to be used for clamping together the joint once it has been assembled and glued (and once the top surface has been made level and smooth by manipulating the two pieces relative to each other with weights and other applied forces). However, it is awkward and difficult to apply and maintain those weights and forces accurately during the surface levelling process and also during the subsequent clamping step. Thus that joining process is generally a two or more person job.

Otherwise a less than perfect joint can be expected, i.e. a perfectly level and flat finished surface for a joint between two sheets will not be provided. Indeed, many kitchen worktops are fitted badly, i.e. with stepped joints, or with filler compensating for the non level joint, or with sanded surfaces to correct such faults.

There is therefore a need for a device that will assist with the perfect alignment of two abutting sheets, that can allow good or perfect joints to be formed between those two sheets by a single person, and with minimal effort.

With the foregoing in mind, the present invention provides a jig for assisting with the alignment of two corresponding surfaces of two adjacent sheets, the jig comprising: a) a first portion, having a first surface for securing directly to the first sheet; and b) a second portion, not overlying the first portion, having a second surface that in use will face the second sheet; and f c) an adjustment device for contacting the second sheet and allowing adjustment of the relative positions of the first and second sheets by movement of the adjustment device relative to both the first and second portions; wherein the adjustment device can, be adjusted at a third surface of the jig and comprises a screwthread, the first and second portions being in fixed positions relative to each other and the second surface being stepped down from the first surface.

Preferably the third surface is arranged at or on the second portion of the jig.

Preferably the jig is a worktop fitting jig.

The step down between the first and second surfaces of the first and second portions can be formed with any desired cross-sectional profile, e.g. a ramp or a curve. Preferably, however, the step is defined by a pair of right angles, with or without sharp corners.

Preferably the first surface of the first portion andlor the second surface of the second portion is/arc planar.

The first surface of the first portion is intended to be secured directly to the first sheet.

This may be achieved by the use of an adhesive. Preferably, however, the first portion further comprises one or more fixing holes for use in securing the first portion of the jig to the first sheet with a screw or nail, or some other such securement device. The one or more fixing holes is preferably pre-formed, but it may be formed through use of the securement device. For example, if a screw or nail is used to secure the first portion to the first sheet then a hole, if not pre-formed, will be formed when the screw or nail is driven through the first portion. Preferably, however, a pre-formed hole is provided.

Preferably the hole has flat sidewalls, i.e. no thread.

Preferably the second portion comprises one or more holes and the adjustment device passes through through one or more of the holes to contact the second sheet. The one or more holes similarly may be pre-formed or may be formed through use of the adjustment device. Preferably one or more of the holes through the second portion are threaded.

However, not all of the holes in the second portion need to be threaded.

Preferably the adjustment device is a bolt. More preferably it is an M8 bolt.

Preferably the bolt is threaded or passed through one of the holes in the second portion for contacting the second sheet. Preferably adjustment or rotation of the bolt at the third surface allows adjustment of the relative positions of the first and second sheets by movement of the bolt, which is in contact with the second sheet, relative to both the first and second portions.

Preferably the bolt has a fixed wing nut on its end for adjustment or rotation of the bolt., although some other handle, lever or manual adjustment device might be provided instead.

Alternatively, the adjustment device may be a screw. If the adjustment device is a screw then it is intended that the screw should be passed through one of the pre-formed holes in the second portion. The screw is for pulling the second sheet towards the jig (or the jig towards the second sheet), whereas the bolt is adapted to push the second sheet away from the jig (or the jig away from the second sheet). The screw is therefore advantageously free to rotate within its hole, whereas the bolt is advantageously threaded into its hole.

One or more holes might be provided for a threaded bolt and one or more separate hole might be provided for a screw.

Preferably the jig's main body is formed of two plates welded, glued or riveted together, with one plate overlapping part of the other plate.

Preferably the plates are aluminium or steel. They may however, be plastic.

Alternatively, the main body may be a one-piece formed or moulded component.

Preferably the main body has a length of no more than 20cm.

Preferably the main body has a width of no more than 8cm.

Preferably the main body has a depth of no more than 2cm.

Preferably the step has a height of no more than 15mm. More preferably the step is between 3 and 8mm high.

Preferably the step is offset from the middle of the longitudinal length of the jig, making the second portion shorter than the first portion. Preferably the second portion is no more than half the length of the first portion.

Preferably the step extends transversely across the width of the jig.

Preferably the holes in the jig are in the main body of the jig, along the longitudinal centreline of the jig. However, if two or more holes are provided in either portion, they might be symmetrically arranged on that portion with respect to that longitudinal centreline, e.g. spaced along it or spaced either side of it, or combinations thereof.

In a further embodiment the invention provides a kit comprising a jig as described above, together with two interchangeable adjustment devices, one adjustment device being a bolt and the other being a screw.

The present invention also provides a method of aligning a surface of a first sheet relative to a corresponding surface of a second sheet, comprising: providing a jig as described above, or a kit as described above; providing a first sheet with a first surface and a second sheet with a corresponding second surface, the first and second surfaces being in approximate alignment with respect to one another; affixing the first portion of the jig to the first sheet on a surface of the first sheet, other than the first surface; applying the adjustment device of the jig or kit against a surface of the second sheet, other than the corresponding second surface, through a hole in the second portion of the jig; and adjusting the adjustment device to adjust the relative positions of the first and second surfaces.

Preferably the two sheets abut one another.

Preferably the first portion of the jig is affixed to the first sheet after the first and second surfaces have been approximately aligned with each other. That fixation, however, might be done before the sheets are approximately aligned with each other.

Preferably, once aligned with the jig, the two sheets are firmly clamped together by one or more longitudinal T-clamps.

Two or more jigs and two or more clamps might be used in the method, whereby one jig might raise the second sheet relative to the first sheet and another jig may lower the second sheet relative to the first sheet, or whereby one jig may raise or lower the second sheet relative to the first sheet to a lesser or greater amount than another jig. This then provides the facility to provide a perfect finished surface along a long length of joint.

The main body of the jig of the invention may be made from wood, plastic, moulded plastic, or metal, e.g. aluminium or steel. It may have a main body that is formed as a single unitary piece, but with separable adjustment devices. Instead, however, the jig may be assembled from two plates that have been glued, welded or riveted together.

It will be appreciated that the present invention allows a single user accurately to align two sheets of material relative to one another, without undue effort, and then to keep that alignment true while the user applies conventional longitudinal T-clamps, or some other fixation device, to those aligned sheets for joining or gluing those sheets together.

Although the present invention is particularly applicable to fitting kitchen (or bathroom) worktops, it should be appreciated that the device herein described can also be used to correctly align two corresponding surfaces of any two adjacent sheets (where access to two sides of at least one of the two sheets is provided during the surface alignment steps.

A specific embodiment of the present invention will now be described, purely by way of example, with reference to the accompanying drawings, in which: Figure 1 shows a perspective view of a jig of a preferred embodiment; Figure 2 shows the jig of Figure 1, together with a securement device and a first adjustment device; Figure 3 is a section through the preferred embodiment showing it in operation, pushing up one sheet relative to another sheet; Figure 4 is a section through the preferred embodiment showing it in an alternative mode of operation, instead pulling down one sheet relative to another sheet; Figure 5 shows a bottom plan view of the preferred embodiment underneath a joint in a work surface, positioned between two conventional longitudinal T-clamp devices; and Figure 6 is a section, similar to Figure 4, where a carcass blocks downward movement of one of the sheets, whereby the screw pulls up the other sheet relative to the blocked sheet; As shown in Figure 1, the jig 10 of this preferred embodiment comprises a main body formed of two metal plates 12, 14 secured together, one on top of the other, for example by welding 16 (see Figure 2). That main body, however, may instead be a molded component. Alternatively it might be two sheets nveted together.

The second plate 14 has two ends 20 and 36 arid a width. They define the limits of a first portion 38 of the jig -the uppermost surface of the jig.

The first plate 12, however, is longer than the second plate 14. The first plate 12, therefore, which underlies that second plate 14, extends beyond one end 20 of the first plate 12 to define a second portion 18 of the jig 10. That second portion also has a top surface. However, it is stepped down from the first portion by the thickness of the second plate.

The step 22 is flat faced, extending transversely across the main body of the jig, and perpendicular to the two top surfaces of the first and second portions of the jig.

The second portion does not overlay the first portion. Instead it starts at the one end 20 of the first plate 12 and it extends towards a free end 34 of the first plate 12.

The other end of the second plate 14 aligns with the other end 36 of the first plate to form the second free end 36 of the main body.

The main body is generally rectangular, with the length of the main body, as measured between the two free ends of the main body, about 12.5cm long and the width of the main body about 5cm wide.

The step is preferably positioned such that the second portion is about 4cm long (and 5cm wide) and the first portion is about 8.5cm long (and 5cm wide).

Each plate is about 5mm deep. Thus the step is about 5mm deep and the maximum depth of the main body is about 1cm deep.

Various holes are provided in the first and second portions 38, 18. In this embodiment, the first portion 38 has two holes 42a and 42b passing through it. They have plain walls, i.e. no thread, and a diameter of 7mm. Those holes are for allowing one or two screws 40 to be passed through the main body of the jig for attaching the first portion 38 to the underside of a first worktop sheet -see Figure 3. Either or both of the holes 42a or 42b can be used for that purpose. Smaller or larger holes might be more appropriate, however, dependent upon the size of the screw to be used. A 7mm hole, however, will readily accommodate a standard size 5.0x40 (or a size 10, 1� inch) cross-head or flat-head (or similar) screw.

The second portion 18 also has a hole in it. Indeed, there are four holes in this embodiment. The first hole is a threaded hole 24, preferably an M8 threaded hole.

Additionally, however, there are three plain sided holes 26, i.e. without a thread. They have a diameter of 6mm. As before, different hole sizes may be preferred, dependent upon the size of screw or bolt to be used.

In this embodiment, the holes in the first portion 38, and the threaded hole and one of the unthreaded holes in the second portion 18 are all aligned along the longitudinal centreline of the main body of the jig 10. The two remaining unthreaded holes in the second portion 18 are then equi-spaced either side of the first unthreaded hole in that second portion.

As shown, the unthreaded holes in the second portion 18 are positioned with their centres spaced 10mm from the free end, and, for the two equi-spaced ones, the adjacent sides of the first plate 12.

The threaded hole 24 in the second portion 18 is positioned with its centre 22mm from the free end of the first plate 12.

The two holes 42a, 42b in the first portion 38 are positioned with their centres 2.5cm and 6.2cm, respectively, from the other end 36 of the jig 10.

All of the holes extend perpendicularly through the two plates 12, 14.

The threaded hole 24 is for receiving a bolt 28 through it. The bolt 28 has a fixed wing nut 30 on its end so that the bolt 28 can be turned by hand. An optional washer 32 can also be used, as shown.

The bolt 28 is for a first use of the jig, as shown in Figure 3. In that use, two worktop sheets 44, 46 that need to be aligned are brought together to form a joint, initially using a conventional cutting/preparation procedure, i.e. with a router and router jig to form clean and smooth abutting edges. However, when the alignment step needs to be carried out, i.e. after applying the glue, but before clamping up the longitudinal T-clamps 45 for tightening the joint, the jig 10 is first used to conectly align the two top surfaces of the worktop. For that the jig is attached to a first one of the sheets -the first sheet 44 -using one or more screw 40 (through one or both of the holes 42a or 42b in the first portion 38). Then the bolt 28 is screwed into the threaded hole 24 from the underside of the jig and brought into contact with the second sheet 46 by rotation of it via the wing nut 30.

To avoid penetration of the underside of the second sheet by the bolt 28, the bolt 28 has a substantially flat end 52. Some other non-penetrating end, however, might be provided instead.

Since the bolt 28 does not penetrate into the second sheet 46, upon touching the second sheet 46, any further rotation 30 of the bolt 28 will provide an adjustment of the position of the second sheet 46 relative to the first sheet 44.

Two or more such jigs might be used for correctly aligning the joint along the full length of the joint. Further, once aligned at a particular jig, a screw might be used through one of the other holes in the second portion for temporarily securing the aligned position at that jig, whereby adjustments can then be made at other jigs without disrupting the alignment at a preceding (secured) jig.

Once the two sheets 44 and 46 are correctly aligned (i.e. by lifting the second sheet 46 relative to the first sheet 44 with the bolt), the clamp (or clamps -see Figure 5) can be tightened to permanently tighten and secure the joint in the usual way (i.e. with pm-applied adhesive along the abutting faces of the two sheets).

In the alternative use shown in Figure 4, as before the jig is brought into contact with and attached to the first sheet 44 via the screw 40, which passes through the hole 42b.

However, instead of the bolt 28, a screw 50 is used for adjusting the second sheet 46 relative to the first sheet 44. That screw 50 is secured and screwed into the second sheet 46 through one of the plain holes 26 in the second portion 18. Then, rotation of the screw in a clockwise direction (for a conventional screw) will causes the second sheet 46 to be pulled down relative to the first sheet 44.

Since the screw is free to move axially within its hole in the second portion, once the alignment has been achieved, a bolt ay then be used to temporarily secure that alignment, in much the same way as discussed above. Then adjustments with second or third (or more) jigs can be made without damaging the alignment at that first jig.

Then, once the two sheets 44 and 46 have been correctly aligned, the longitudinal T-clamp (or clamps -see Figure 5) can be tightened to permanently secure the joint in the usual way.

It should also be observed that that it is not unusual when fitting a worktop, for example in a kitchen, for an edge of one of the two sheets to be lying near a side of an underlying carcass 48. The top of a carcass 48 is shown schematically in Figure 6, with the relatively higher sheet 46 on the carcass 48, and with an unrestrained sheet 44 being located lower relative thereto.

Because the higher sheet 46 is resting against the top edge f the carcass 48, it will not be free to move downwards for moving it into alignment with the lower sheet 44.

Further, because of the presence of the carcass 48, only limited access at the underside of the edge of the higher sheet 46 is available for the jig 10, whereby the jig's first portion 38 will not suitably fit onto the underside of the higher sheet 46 for using the bolt 28 to lift the lower sheet 44 into alignment with the higher sheet 46. Thus the jig 10 will then be used in a third mode of operation -the first portion 38 of the jig 10 is screwed to the underside of the lower sheet 44, and a screw 50 is then used to lift the lower sheet 44 and the jig 10 together, as shown by the arrow, so as to allow the top surfaces of the two sheets 44,46 to be brought into alignment.

Similarly, there can be corresponding situations (not shown) where the lower sheet is blocked from upward movement, for example by being already screwed down to the carcass, and with the carcass too close to the edge of that lower sheet, whereby the first portion 38 of the jig 10 cannot be fitted to the underside of that lower sheet, thus preventing use of the jig, with the screw, for pulling down the higher sheet. In that situation, the jig 10 can still be used for aligning the two sheets 44, 46. However, to do that the jig 10 is instead fixed to the underside of the higher sheet, and the bolt 28 is used against the underside of the lower sheet to push down the higher sheet and the jig, together, whereby the top surfaces of the two sheets 44, 46 can still be brought into alignment using the jig 10.

It will be also appreciated that in some circumstances one area of a joint might need a first sheet to be raised relative to the other sheet, and another area might need that same sheet to be lowered relative to that other sheet. Thus multiple jigs might be used for any one joint, with various combinations of modes of use, as described above, being implemented for each of the jigs.

The use of a bolt or screw for the adjustment device, both of which cause controlled relative movements by the interaction of their screwthreads with either the jig or the sheet, allow accurate and fine adjustment of the respective levels of the two adjacent sheets relative to one another without significant effort by the user. Therefore, a perfectly level finished surface is easy to achieve when using the present invention.

Since two holes (one threaded for the bolt and one for a screw) are provided in the second portion 18, it is possible to first lift (e.g. with the bolt) and then to lower (e.g. with the screw) one sheet relative to the other sheet (or vice versa) without removing the bolt or screw from either the jig or the sheet into which it is secured. This might become necessary for example upon adjusting the level elsewhere with a second jig if no temporary securement at the first jig is put in place. That is because the level adjustment elsewhere might then cause the initial alignment at the first jig to be knocked off-true. It is observed, however, that carrying out the alignment in this manner might prove to be quicker than the above described method using temporary securement after each alignment step.

Finally, although more than one hole is provided in each portion of the jig in the illustrated embodiment, it should be appreciated that one hole might be sufficient, especially where it is merely necessary either to raise or lower the second sheet relative to the first sheet at a single location along the joint.

The present invention has been described above purely by way of example. It should be noted that modifications in detail may be made within the scope of the invention.

Claims

Claims 1. A jig for assisting with the alignment of two corresponding surfaces of two adjacent sheets, the jig comprising: a) a first portion, having a first surface for securing directly to the first sheet; and b) a second portion, not overlying the first portion, having a second surface that in use will face the second sheet; and c) an adjustment device for contacting the second sheet and allowing adjustment of the relative positions of the first and second sheets by movement of the adjustment device relative to both the first and second portions; wherein the adjustment device can be adjusted at a third surface of the jig and comprises a screwthread, the first and second portions being in fixed positions relative to each other and the second surface being stepped down from the first surface.
2. The jig according to claim 1, wherein the step is formed by a pair of right angles.
3. The jig according to any one of the preceding claims, wherein the first surface of the first portion is planar.
4. The jig according to any one of the preceding claims, wherein the second surface of the second portion is planar.
5. The jig according to any one of the preceding claims, wherein the first portion further comprises one or more fixing holes for use in securing the first portion of the jig to the first sheet.
6. The jig accOrding to any one of the preceding claims, wherein the screwthread is provided within the hole.
7. The jig according to any one of the preceding claims, wherein the second portion comprises at least two holes.
8. The jig according to claim 7, wherein at least two holes on the jig are threaded.
9. The jig according to any one of the preceding claims, wherein the adjustment mechanism is a bolt.
10. The jig according to claim 9, wherein the bolt is an M8 bolt.
II. The jig according to claim 9 or claim 10, wherein the bolt comprises a fixed wing nut for adjustment or rotation of the bolt.
12. The jig according to any one of claims 1 to 8, wherein the adjustment mechanism is a screw.
13. The jig according to any one of the preceding claims, wherein the jig's main body is formed of two plates secured together with one plate overlapping the other plate.
14. The jig according to any one of claims 1 to 12, wherein the jig's body is a one-piece formed or moulded component.
15. The jig according to any one of the preceding claims, wherein the jig is made of metal.
16. The jig according to claim 15, wherein the jig is made of aluminium or steel.
17. The jig according to any one of claims 1 to 14, wherein the jig is made of plastic.
18. The jig according to any one of the preceding claims, wherein the main body has a length of no more than 20cm.
19. The jig according to any one of the preceding claims, wherein the main body has a width of no more than 8cm.
20. The jig according to any one of the preceding claims, wherein the main body has a depth of no more than 2cm.
21. The jig according to any one of the preceding claims, wherein the step has a height of no more than 15mm.
22. The jig according to any one of the preceding claims, wherein the step is offset from the middle of the longitudinal length of the jig, making the second portion shorter than the first portion.
23. A kit comprising a jig according to any one of the preceding claims, together with two interchangeable adjustment mechanisms, one adjustment mechanism being a bolt and the other being a screw.
24. A method of aligning a surface of a first sheet relative to a corresponding surface of a second sheet, comprising: providing a jig as defined in any one of claims 1 to 22, or a kit as defined in claim 23; providing a first sheet with a first surface and a second sheet with a corresponding second surface, the first and second surfaces being in approximate alignment with respect to one another; affixing the first portion of the jig to the first sheet on a surface of the first sheet, other than the first surface; applying the adjustment mechanism of the jig or kit against a surface of the second sheet, other than the second surface, through the hole in the second portion of the jig; and adjusting the adjustment mechanism to adjust the relative positions of the first and second surfaces.
25. A jig for assisting with the fitting of a kitchen worktop substantially as hereinbefore described with reference to the accompanying drawings.
26. A method of fitting a kitchen worktop substantially as hereinbefore described with reference to the accompanying drawings.