| |
| United States Patent
|
7,344,433 |
| Wilson |
March 18, 2008 |
System for matched-stone cover plates
Abstract
A cover plate system for making custom natural stone cover plates
for electrical outlets, wall switches and other outlets and openings
over which it is desired to place a natural stone cover plate. The
natural stone cover plates are made from quarried stone, cultured
stone, and natural rock materials such as terrazzo, marble, and
granite preferably supplied by the homeowner, or end user, to a
central factory, then manufactured, then shipped back to the end
user to match other such material being used in the end user's
building.
| Inventors: |
Wilson; Ronald J.
(Phoenix, AZ) |
| Appl. No.:
|
10/196,628 |
| Filed: |
July 15, 2002 |
Related U.S. Patent Documents
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Application Number |
Filing Date |
Patent Number |
Issue Date |
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60305210 |
Jul., 2001 |
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| Current U.S.
Class: |
451/41 ;
125/1; 174/66; 174/67 |
| Current
International Class: |
B24B
1/00 (20060101); H02G 3/14 (20060101) |
| Field of
Search: |
451/41,285,286-290 125/1 174/66 |
References Cited
[Referenced By]
U.S. Patent
Documents
Primary Examiner: Wilson; Lee D.
Assistant Examiner: Ojini; Anthony
Attorney, Agent or Firm:
Stoneman Volk Patent Group Stoneman; Martin L.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATION
The present application is related to applicant's prior U.S.
Provisional Application No. 60/305,210, filed Jul. 13, 2001,
entitled "SYSTEM FOR MATCHED-STONE COVER PLATES", the contents of
which are herein incorporated by reference and are not admitted to
be prior art with respect to the present invention by their mention
in this cross-reference section.
Claims
What is claimed is:
1. A system for providing at least one stony custom cover plate to
at least one customer for use with at least one electrical box
holding at least one electrical service device for use with such
cover plate, comprising, in combination: a) receiving a quantity of
desired stony material; b) reducing each received item of such
material so requiring down to at least one blank of a working width
for easier handling; c) reducing the thickness of each such blank to
a desired thickness for a desired such cover plate; d) reducing each
such blank to at least one plate to provide the desired cover plate
dimensions; e) drilling at least one hole through such thickness of
such plate; f) machining out such at least one hole to form at least
one larger aperture through such plate adapted to expose such at
least one electrical service device for use; and g) buffing at least
one plate edge.
2. The system according to claim 1 wherein such stony material
consists essentially of natural stone.
3. The system according to claim 2 wherein such reducing down to
blanks is accomplished using a common table saw.
4. The system according to claim 3 wherein: a) such desired
thickness is about one-eighth inch to about three-eighths inch; and
b) at least one jig is used to hold such plate during the machining
step.
5. The system according to claim 2 wherein such desired thickness is
about one-eighth inch to about three-eighths inch.
6. The system according to claim 5 wherein such desired thickness is
about three-eighths inch.
7. The system according to claim 6 further comprising: a) reducing
such thickness of such plate adjacent such aperture, to form a
recess, in such manner that, if such cover plate is attached over a
particular such electrical service device having a particular outer
contour, an outer surface of such cover plate is substantially
aligned with an outer surface of such electrical service device.
8. The system according to claim 7 wherein: such recess is formed by
routing.
9. The system according to claim 7 wherein reducing the thickness of
each such blank to a desired thickness for a desired such cover
plate comprises, at least partially, grinding a rear unfinished
surface of such plate, using a surface grinder, to achieve such
desired thickness.
10. The system according to claim 9 wherein such step of surface
grinding comprises use of a vacuum-assisted chuck.
11. The system according to claim 7 comprising the following ordered
steps: a) drilling at least one pilot hole for routing; b) routing
such at least one such recess in such rear surface; c) drilling, in
such front surface, at least one screw-mounting hole; d) chamfering
such at least one screw-mounting hole; e) routing such at least one
aperture; and f) chamfering at least one peripheral edge of such
plate.
12. A natural stone article having a shape manufactured in
accordance with the process of claim 7.
13. The system according to claim 2 wherein at least one jig is used
to hold the plate during at least one such machining step.
14. A stony-material article having a shape manufactured in
accordance with the process of claim 1.
Description
BACKGROUND
This invention relates to a cover plate system for making custom
natural stone cover plates for electrical outlets, wall switches and
other outlets and openings in which it is desired to place a natural
stone cover. More particularly, this invention relates to such a
system and method for providing such cover plates matching the
natural stone(s), even the exact "lot" of such stones, used, e.g.,
as tiles for floors, countertops, etc., provided in a customer's
residence or business location. The cover plates may be made from
quarried stone, cultured stone, and natural rock materials such as
terrazzo, marble, and granite and other stone-like brittle materials
(the above materials all are herein referred to only as natural
stone).
Typically, cover plates are standardized, with the size of the
plates, outlet and switch openings and location of mounting holes
being fixed for the majority of electrical outlets and switches.
Cover plates are typically made of plastic, are inexpensive, and
come in an extremely limited color selection. Homeowners or other
users may desire to utilize expensive custom countertops, wall
coverings or flooring made from natural stone. These materials
typically cost thousands or tens of thousands of dollars. It is
generally undesirable to select a plastic or plain cover plate and
have it placed next to the expensive natural stone.
Heretofore, there have been a limited number of options for a more
desirable cover plate. Some cover plates are pre-manufactured using
wood, ceramic or other materials; however, persons desiring to match
the custom natural stone installed in their building have little
choice for cover plates. For example, U.S. Pat. No. 6,037,542
(further referred only as the '542 patent) provides for an upper
substrate bonded to a lower substrate such as an existing standard
cover plate. This patent does not provide a method for creating a
solid natural stone cover plate using natural stone material
supplied by the homeowner, or end user, to match other such material
being used in the end user's building. Further the '542 patent does
not disclose a method for reducing the thickness of natural stone
nor a method of cutting such natural stone to match a standardized
cover plate, but simply states that substrates must be cut, placed
and adhered.
Natural stone is unique; and even natural stone pulled from the same
quarry may vary in color and texture. Even further, natural stone
may be very brittle and has a multitude of texture differences which
make it a difficult product to manipulate. It is especially
pertinent, that, for certain natural stones and stony materials,
there will often be certain minimum dimensions required to work with
such material without destruction or other breaking; thus,
manufacturing techniques may be required beyond those for normal
thin cover plates of other materials. Therefore, a need exists to
manufacture cover plates from natural stone or other such quarry
material made to match the material utilized in a user's rooms.
These "tile" materials commonly are supplied in thickness of
three-eighths inch to two inches thick; therefore a need exists to
provide a method of reducing the thickness of the material to
incorporate the cover plate onto the outlet. Further, a need exists
to provide such natural stone cover plates which may be installed on
any custom or standardized outlet and switch, including screw
mounting holes.
OBJECTS OF THE INVENTION
A primary object and feature of the present invention is to provide
a cover plate system for making custom cover plates from quarried
stone, cultured stone, and natural rock materials such as terrazzo,
travertine, marble, and granite or from "tiles" of said materials
matching those used in a user's rooms.
It is a further object and feature of the present invention to
provide such a system which utilizes a customer's materials
(preferably supplied by the homeowner or end user) so as to match
such material in both color and texture in making such cover plates.
It is a further object and feature of the present invention to
provide such a system which will provide a method of cutting,
shaping and drilling the material to incorporate the cover plate to
be installed on any custom or standardized outlet and switch,
including screw mounting holes.
A further primary object and feature of the present invention is to
provide such a system which is efficient, inexpensive, and handy.
Other objects and features of this invention will become apparent
with reference to the following descriptions.
SUMMARY OF THE INVENTION
In accordance with a preferred embodiment hereof, this invention
provides a system for providing at least one stony custom cover
plate to at least one customer for use with at least one electrical
box holding at least one electrical service device for use with such
cover plate, comprising, in combination: providing at least one
central factory for cover plate manufacture; advertising such cover
plate manufacture over a wide area; arranging for placement of
customer orders with such factory for a customer-specified number of
fully-size-specified cover plates; arranging for receiving shipment
at such factory of sufficient stony material matching the customer's
hard surface decor ("tile" materials) for at least one particular
area to permit manufacture of the ordered cover plates;
manufacturing at such factory such ordered cover plates; and
arranging for the manufactured cover plates to be delivered to the
customer.
It also provides such a system further comprising: arranging for the
return of factory-unused customer's material to the customer. And,
provides such a system wherein such stony material comprises natural
stone material.
In accordance with another preferred embodiment hereof, this
invention provides a system for providing at least one stony custom
cover plate to at least one customer for use with at least one
electrical box holding at least one electrical service device for
use with such cover plate, comprising, in combination: receiving a
quantity of desired stony material; reducing each received item of
such material so requiring down to at least one blank of a working
width for easier handling; reducing the thickness of each such blank
to a desired thickness for a desired such cover plate; reducing each
such blank to at least one plate to provide the desired cover plate
dimensions; drilling at least one hole through such thickness of
such plate; machining out such at least one hole to form at least
one larger aperture through such plate adapted to expose such at
least one electrical service device for use; and buffing at least
one plate edge.
Furthermore, it provides such a system wherein such stony material
consists essentially of natural stone. It also provides such a
system wherein such reducing down to blanks is accomplished using a
common table saw. Even further, it provides such a system wherein
such desired thickness is about one-eighth inch to about
three-eighths inch. Still further, it provides such a system wherein
such desired thickness is about three-eighths inch.
Moreover, it provides such a system further comprising: reducing
such thickness of such plate adjacent such aperture, to form a
recess, in such manner that, if such cover plate is attached over a
particular such electrical service device having a particular outer
contour, an outer surface of such cover plate is substantially
aligned with an outer surface of such electrical service device.
And, it provides wherein such recess is formed by routing.
Even further, it provides such a system wherein reducing the
thickness of each such blank to a desired thickness for a desired
such cover plate comprises, at least partially, grinding a rear
unfinished surface of such plate, using a surface grinder, to
achieve such desired thickness.
Additionally, it provides such a system comprising the following
ordered steps: drilling at least one pilot hole for routing; routing
such at least one such recess in such rear surface; drilling, in
such front surface, at least one screw-mounting hole; chamfering
such at least one screw-mounting hole; routing such at least one
aperture; and chamfering at least one peripheral edge of such plate.
Still further it provides such a system wherein at least one jig is
used to hold the plate during at least one such machining step. And,
it provides such a system wherein: such desired thickness is about
one-eighth inch to about three-eighths inch; and at least one jig is
used to hold such plate during the machining step.
In accordance with another preferred embodiment hereof, this
invention provides a stony-material article having a shape
manufactured in accordance with the herein described processes.
In accordance with another preferred embodiment hereof, this
invention provides a natural stone article having a shape
manufactured in accordance with the herein described processes.
In accordance with yet another preferred embodiment hereof, this
invention provides a system for providing custom cover plates,
comprising: a product comprising entirely natural stone; wherein
such product has a shape permitting efficient and aesthetic use,
without further modification of such natural stone material, of such
product as a wall cover plate using standard hardware and fitting
standard electrical receptacle boxes. It also provides such a system
further comprising associated standard hardware for installation.
Furthermore, it provides such a system wherein such product and
hardware are in an installed condition; and, wherein such product
comprises at least one aperture for electrical terminals; and
further wherein such product comprises multiple apertures for
electrical terminals. It even provides such a system wherein such
product comprises at least one aperture for an attachment; and
wherein such step of surface grinding comprises use of a
vacuum-assisted chuck.
In accordance with still another preferred embodiment hereof, this
invention provides a vacuum-assisted chuck comprising at least one
substantially-hollow boxlike body wherein: at least one upper
surface of such chuck comprises a set of apertures structured and
arranged to hold, using a vacuum created from a wet/dry shop vacuum
device, at least one stony custom cover plate during a surface
grinding step. It also provides such a system further comprising a
set of grooves connecting all of such set of apertures on such at
least one upper surface of such chuck. And, it provides such a
system wherein at least one stony custom cover plate comprises at
least one natural stone cover plate.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a cover plate installed above a
custom natural stone counter top according to a preferred embodiment
of the present invention.
FIG. 2 is a front view of a natural stone cover plate according to a
preferred embodiment of the present invention.
FIG. 3 is a perspective view of natural stone slab material as it is
commonly shipped according to a preferred embodiment of the present
invention.
FIG. 4 is a perspective view of pre-cut natural stone material tiles
as they are commonly shipped according to a preferred embodiment of
the present invention.
FIG. 5 is a perspective view of a step in the method of
manufacturing the cover plates illustrating a first horizontal
cutting process according to a preferred embodiment of the present
invention.
FIG. 6 is a perspective view of another step in the method of
manufacturing the cover plates illustrating a first vertical cutting
process according to a preferred embodiment of the present
invention.
FIG. 7 is a perspective view of a sized blank cover plate created by
the method of manufacturing the cover plates resulting from a second
horizontal cutting process according to a preferred embodiment of
the present invention.
FIG. 8 is a perspective view of yet another step in the method of
manufacturing the cover plates illustrating the drilling of pilot
and screw holes according to a preferred embodiment of the present
invention.
FIG. 9 is a perspective view of still another step in the method of
manufacturing the cover plates illustrating use of a custom jig in
combination with a standard cover plate as a pattern according to a
preferred embodiment of the present invention.
FIG. 10 is a perspective view of a further step in the method of
manufacturing the cover plates illustrating use of the custom jig of
FIG. 9 according to a preferred embodiment of the present invention.
FIG. 11 is a perspective view of a further step in the method of
manufacturing the cover plates illustrating use of a router (a
preferred machine tool) in combination with the custom jig of FIG.
10 according to a preferred embodiment of the present invention.
FIG. 12 is a sectional view through section 12--12 of FIG. 11.
FIG. 13 is a perspective view of a cover plate after being removed
from the jig of FIG. 11 according to a preferred embodiment of the
present invention.
FIG. 14 is a perspective view of the last step in finishing the
cover plate according to a preferred embodiment of the present
invention.
FIG. 15 is a rear view of a natural stone cover plate according to
another preferred embodiment of the present invention.
FIG. 16 is a front view of the natural stone cover plate of FIG. 15.
FIG. 17 is a side view, partially in section, through section 17--17
of FIG. 16.
FIG. 18 is a perspective view of a blank natural stone plate
illustrating a first step in a method of making the natural stone
cover plate of FIG. 15 according to another preferred embodiment of
the present invention.
FIG. 19 is a perspective view of another step in the method of
making the natural stone cover plate of FIG. 15 illustrating a
method of reducing the thickness of the stone utilizing horizontal
grinding of the blank plate.
FIG. 20 is a perspective view of another step in the method of
making the natural stone cover plate of FIG. 15 illustrating
drilling of a center pilot hole.
FIG. 21 is a perspective view of yet another step in the method of
making the natural stone cover plate of FIG. 15 illustrating use of
a routing jig.
FIG. 22 is a perspective view of yet another step in the method of
making the natural stone cover plate of FIG. 15 illustrating use of
a router.
FIG. 23 is a sectional view through section 23--23 of FIG. 22.
FIG. 24 is a perspective view of another step in the method of
making the natural stone cover plate of FIG. 15 illustrating
drilling of screw holes and screw recesses.
FIG. 25 is a perspective view of yet another step in the method of
making the natural stone cover plate of FIG. 15 illustrating
drilling of screw recesses and use of another jig.
FIG. 26 is a perspective view of another step in the method of
making the natural stone cover plate of FIG. 15 illustrating another
routing step.
FIG. 27 is a sectional view through section 27--27 of FIG. 26.
FIG. 28 is a side view, partially in section, of another step in the
method of making the natural stone cover plate of FIG. 15
illustrating use of a saw for beveling the edges of the cover plate.
FIG. 29 is a side view, partially in section, of another step in the
method of making the natural stone cover plate of FIG. 15
illustrating use of a saw for rounding the edges of the cover plate.
FIG. 30 is a perspective view of a final step in the method of
making the natural stone cover plate of FIG. 15 illustrating a
polishing means.
FIG. 31 is a perspective view of a vacuum-assisted chuck used to
hold the natural stone cover plate while grinding.
FIG. 32 is an exploded perspective view of the vacuum-assisted chuck
of FIG. 31.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
Reference is now made to the drawings. FIG. 1 is a perspective view
of a cover plate 120 of the cover plate system 124 installed above a
custom natural stone counter top 122 according to a preferred
embodiment of the present invention (embodying herein wherein such
product and hardware are in an installed condition). Preferably, the
present invention provides a cover plate system 124 for making
custom cover plates for electrical outlets, wall switches and other
such outlets. The cover plates are made from quarried stone,
cultured stone, and natural rock materials such as terrazzo, marble,
travertine and granite (the above materials are all herein referred
to only as natural stone, however, embody herein a stony material).
Preferably, the natural stone material is supplied by the homeowner,
or end user, to match other such material being used in the end
user's building.
The following description relates to all such cover plates,
represented by two illustrated styles, cover plate 120 (see FIG. 2
and FIG. 13) and cover plate 200 (see FIG. 15) for representation
purposes. Those knowledgeable in the art will recognize that there
are multiple styles and sizes of such cover plates.
FIG. 2 is a front view of a natural stone cover plate 120 according
to a preferred embodiment of the present invention. Preferably,
cover plate 120 is sized in width and height similar to standard
cover plates such as is well known in the art. Preferably, a
standard off-the-shelf plastic cover plate is used to pattern the
custom natural stone cover plate 120. Such cover plates typically
have one or more aperture(s) 126 (embodying herein wherein such
product comprises at least one aperture for electrical terminals;
and embodying herein wherein such product comprises multiple
apertures for electrical terminals), for the switch or electrical
outlets(s) and one or more apertures 128 for attachment, typically
by screws (embodying herein wherein such product comprises at least
one aperture for an attachment). It is noted that the term aperture
herein may include more than one aperture. It is also noted that all
the associated hardware to install typical cover plates is intended
to be used and included to install the natural stone cover plates of
the present invention (embodying herein wherein such product has a
shape permitting efficient and aesthetic use, without further
modification of such natural stone material, of such product as a
wall cover plate using standard hardware and fitting standard
electrical receptacle boxes).
FIG. 3 is a perspective view of natural stone slab(s) 130, such as
quarried stone as it is commonly shipped according to a preferred
embodiment of the present invention. FIG. 4 is a perspective view of
pre-cut natural stone material tiles 132, such a marble and terrazzo
as they are commonly shipped according to a preferred embodiment of
the present invention. Typically, natural stone slabs 130 are
provided in a thickness of one-half inch to two inches in thickness
and very in size from about two to twenty-five square feet.
Typically, pre-cut natural stone material tiles 132 are provided in
three-eighths to three-quarter inch thicknesses and vary in size
from about one to two square feet. Preferably, a cover plate 120
from natural stone should be milled to a thickness of about
one-eighth of an inch to three-eighths of an inch to properly fit
over a switch or outlet. The width and height of the cover plate 120
will vary depending on the size of the outlet box that the cover
plate 120 will be attached to. Typically, such cover plates 120
range from a single plate (as illustrated) which covers a single
gang electrical box, sized at about three inches in width by four
and one-half inches in height, to a four gang box cover plate sized
at about twelve inches wide by four and one-half inches in height.
FIG. 5 is a perspective view of a step in the method of
manufacturing the cover plates 120 illustrating a first horizontal
cutting process 134 according to a preferred embodiment of the
present invention. Preferably, the natural stone slab 130 and/or the
natural stone material tiles 132 are cut down to a working width by
height dimension, such that the natural stone pieces 136 may be more
easily handled after being received for processing at the
manufacturing site (this arrangement embodies herein receiving a
quantity of desired stony material). Such material may be very heavy
and cumbersome to machine. Preferably, the natural stone pieces 136
are cut into a working piece called a blank 140 (as best illustrated
in FIG. 7) with a table saw 138 as illustrated in FIG. 5 (this
arrangement embodies herein reducing each received item of such
material so requiring down to at least one blank of a working width
for easier handling).
Preferably, the blanks 140 are cut to a working width of about three
and one-half inches (based on whatever the finish height of the
cover plate 120 is intended). The length of the blank 140 may vary
depending on how many cover plates 120 are to be made from the blank
140. Preferably, a common table saw is used to cut the blanks 140
from the natural stone pieces 136 (embodying herein wherein such
reducing down to blanks is accomplished using a common table saw).
Such table saws are well known in the art and are most often used
for woodworking. Preferably, the table saw has a large enough motor
141 to cut through the natural stone pieces 136 without binding. The
exact horsepower may vary depending on the requirements of the
specific natural stone piece 136, however a power range from about
three-quarter horsepower to seven and one-half horsepower (with
appropriate gearing) is generally sufficient. Preferably, the stone
may be cut with either a wet method or dry method saw blade 142.
Under appropriate circumstances, other cutting methods may suffice
(such as a high pressure water saw used to cut the stone from a
quarry). The preferred embodiment discussed herein is the best and
least expensive method of cutting discovered to date by the
applicant. In a wet method the saw blade 142 cuts the stone pieces
utilizing a combination of a coolant (typically water) for cooling
and a diamond blade. Such wet method saw blades typically have no
cutting teeth and may be preferably used on materials that tend to
chip using the dry method. In the dry method the saw blade 142 cuts
the material without any coolant. Stone materials may respond
differently to either method and as such the chosen method will
depend on the preference of the user. In the illustrated embodiment
a dry saw blade 142 is utilized. Preferably, the dry saw blade is a
60-tooth carbide blade typically used for cutting wood; however,
those knowledgeable in the art could select, without undue
experimentation, a multitude of available saw blades that would
suffice.
The next step in the method of manufacturing the cover plates 120 is
illustrated in FIG. 6. FIG. 6 is a perspective view of another step
in the method of manufacturing the cover plates 120 illustrating a
first vertical cutting process 144 according to a preferred
embodiment of the present invention. Preferably, the blank 140 is
now cut or milled to the preferred thickness (embodying herein
reducing the thickness of each such blank to a desired thickness for
a desired such cover plate). In the illustrated embodiment of FIG.
6, the blank 140 is inserted into a holder 146. Holder 146 is
preferably a mortise and tenon clamp which slidably attaches to the
saw table 148 and is capable of holding the blank 140 in a
substantially vertical position, as shown. Under appropriate
circumstances other types of holders may suffice. Preferably, the
saw blade is adjusted in height to accommodate the size of the blank
140. In the illustrated embodiment of FIG. 6, the blank 140 is of a
height in which one-half will be cut at a time. The preferred manner
in which the material is removed by the saw blade may vary depending
on the type of blade used, size of the blade (8'', 10'', etc.) and
horsepower of the motor 141. For example, if an eight-inch diameter
saw blade 150 is used, a blank 140 that is three and one-half inches
wide (vertical in the holder) could be milled wholly each pass of
the saw blade 150; however, a blank 140 of four and one-half inches
in height (similar to that illustrated in FIG. 6) would preferably
be milled down by setting the height of the saw blade 150 such that
one-half of the blank 140 width (vertical in the holder) would be
milled each pass. Under appropriate circumstances, other sawing
methods may suffice. Preferably, the blank 140 is pushed passed the
saw blade 150 such that an increment of about one-sixteenth to
one-eighth of an inch of the blank 140 material is removed on each
pass. Preferably, the sawing process continues until this blank 140
is the desired thickness (dimension). Preferably, the desired
thickness is about one-eighth inch to about three-eighths inch. Most
preferably, about three-eighths inch (embodying herein such desired
thickness is about one-eighth inch to about three-eighths inch).
FIG. 7 is a perspective view of a sized blank cover plate 140
created by the method of manufacturing the cover plates resulting
from a second horizontal cutting process according to a preferred
embodiment of the present invention. Preferably, after the blank has
been milled, the actual cover plate 120 size is cut by using the
table saw 138 in a second horizontal cutting process resulting in a
sized blank cover plate 140 (this arrangement embodies herein
reducing each such blank to at least one plate to provide the
desired cover plate dimensions).
FIG. 8 is a perspective view of yet another step in the method of
manufacturing the cover plate 120 illustrating the drilling of pilot
holes 154 and aperture 156 according to a preferred embodiment of
the present invention (embodying herein drilling at least one hole
through such thickness of such plate). Preferably, the next step in
the method of manufacturing the cover plates 120 is to utilize a
drill press 158 and drill bits 160 to drill the pilot holes 154 and
aperture 156. Preferably blank 140 is set in a jig 162 (a term used
in the art to describe a device used to maintain mechanically the
correct positional relationship between a piece of work and the tool
or between parts of work during assembly) made to hold the blank 140
motionless and in such a location as to match the jig 164 and which
corresponds to the apertures 168 and aperture 172 on standard cover
plate 166 used as a pattern and illustrated in FIG. 9 (the above
arrangement embodies herein at least one jig is used to hold such
plate during the machining step). Preferably, the aperture 156 is
drilled first through the front face to assist in preventing
breakage in the blank 140 and future machining. The aperture 156
will become aperture 128 when the cover plate 120 is finished. The
aperture 156 is typically used to insert a connector such as a screw
through the aperture 156 and then thread the screw into an
electrical outlet box (this arrangement embodies herein drilling, in
such front surface, at least one screw-mounting hole). Such
connections are well known in the art. Preferably, aperture(s) 156
has a slight countersink (not shown) applied on the blank front face
152, also machined by the drill press 158. The countersink (chamfer)
is applied to allow the screw to set flush with the face of the
finished cover plate 120 (this arrangement embodies chamfering such
at least one screw-mounting hole). Preferably, the aperture 156 is
about six-thirty-seconds ( 6/32) of an inch in diameter to fit the
majority of commonly used electrical screws. The selection of a
drill bit 160 to drill such a diameter aperture 156 is well known by
those knowledgeable in the art and will not be further discussed.
Under appropriate circumstances other connection methods of
attaching the cover plate 120 to an electrical outlet box or other
desired device may suffice without detracting from the present
invention.
Preferably, the next step in the method of manufacturing the cover
plates 120 is to drill pilot holes 154 for the future step of using
a router 180 (see FIG. 11) or other similar machining tool to cut
out the apertures 126. Preferably, such pilot holes 154 are located
by centering the drill bit 160 in the location of the future
apertures 126 which correspond to the apertures 168 on standard
cover plate 166 used as a pattern and illustrated in FIG. 9.
Preferably, the pilot holes 154 are sized to allow the cutting bit
of the router 180 to pass through them (the above-described
arrangement embodies herein drilling at least one pilot hole for
routing). Subsequent to the completion of the drilling, the blank
140 will be referred to as unfinished cover plate 170.
Reference is now made to FIGS. 9 11. FIG. 9 is a perspective view of
still another step in the method of manufacturing the cover plate
120 illustrating use of a custom jig 164 in combination with a
standard cover plate 166 (referring herein to any cover plate which
is desired to be used as a pattern for the cover plate 120) as a
pattern according to a preferred embodiment of the present
invention. FIG. 10 is a perspective view of a further step in the
method of manufacturing the cover plate 120 illustrating use of the
custom jig 164 of FIG. 9 according to a preferred embodiment of the
present invention. Preferably, unfinished cover plate 170 is removed
from jig 162 and placed in jig 164, as illustrated in FIG. 9 and
FIG. 10.
FIG. 11 is a perspective view of a further step in the method of
manufacturing the cover plate 120 illustrating use of a router 180
(for machining) in combination with the custom jig 164 of FIG. 10
according to a preferred embodiment of the present invention.
Preferably, unfinished cover plate 170 is removed from jig 162 and
placed in jig 164, as illustrated in FIG. 9 and FIG. 10.
Preferably, jig 164 comprises two layers 174 and 176. Preferably,
layer 174 comprises an opening 178 which is cut to hold a standard
cover plate 166, as shown (also see FIG. 12). Preferably, layer 174
comprises a standard cover plate 166. Preferably, layer 176
comprises an opening 182 which is cut to hold unfinished cover plate
170. Preferably, the opening 178 and opening 182 are equal in size.
Under appropriate circumstances other arrangements may suffice.
Preferably, jig 164 is clamped or held in place such that a router
180 or other appropriate machining tool may be used to cut cover
plate 170 while placed in jig 164. Similar clamping means are well
known by those skilled in the art.
Preferably, router 180 utilizes a straight cutting blade 184 with a
bearing 186, also known in the art as a flush trim bit 188.
Selection of a proper size is dependent on the router tool and
aperture size to be cut and such selection may be readily made by
those skilled in the art. For example, a one-half horsepower router
using a one-quarter inch shank cutting an outlet aperture such as
illustrated in FIG. 9 would preferably use a flush trim bit with a
one-quarter inch shank having a three-eighths inch cutting diameter
and a one-half inch cutting length.
FIG. 12 is a sectional view through section 12--12 of FIG. 11.
Preferably, a user 190 (or an appropriate computer program) directs
router 180 such that the bearing 186 rides along the standard cover
plate 166 apertures 168 and assists in guiding the cutting blade 184
such that the cutting blade 184 only removes or cuts the desired
material from the unfinished cover plate 170. Such routing skill is
well known by those knowledgeable in the art and is quite common in
the woodworking industry.
FIG. 13 is a perspective view of a cover plate 120 after being
removed from the jig 164 of FIG. 11 according to a preferred
embodiment of the present invention. FIG. 14 is a perspective view
of the finishing step 199 in finishing the cover plate 120 according
to a preferred embodiment of the present invention. Preferably, the
cover plate 120 is now ready for finishing. Preferably, the edges
192 and 194 are either rounded or eased using either a router 180
with a rounding bit (not shown) or a polishing/grinder tool 196 as
shown in FIG. 14 embodying herein chamfering at least one peripheral
edge of such plate). Preferably, by utilizing varying abrasive grit
and polishing pads 198 that may be attached to the polishing/grinder
tool 196, the cover plate 120 may be finished as desired. Because
each natural stone material reacts differently and each user 190 may
desire to apply more or less effort into the finishing step 199
process, the grit and time will vary to accomplish this last step.
Preferably, an abrasive grit from about 40 to about 50,000 microns
is used in the sanding and polishing of the finishing step 199 (this
arrangement embodies herein buffing at least one plate edge).
Recently, manufacturers of outlets, and some switches, have started
to make such outlets and switches with a unitary front plate rather
than separate portions, as had been the standard in the past.
Consequently, cover plates are required with a singular, typically
larger, opening through which such outlets and plates may fit. The
below described embodiment is directed towards natural stone cover
plates for use with such singular openings but may also be used,
under appropriate circumstances, with other styles of cover plates.
FIG. 15 is a rear view of a natural stone cover plate 200 according
to another preferred embodiment of the present invention. FIG. 16 is
a front view of the natural stone cover plate 200 of FIG. 15. FIG.
17 is a side view, partially in section, through section 17--17 of
FIG. 16. (The above-described Figures embody herein a stony-material
article having a shape manufactured in accordance with the processes
described herein; and embodying herein a natural stone article
having a shape manufactured in accordance with the processes
described herein).
Preferably, in this embodiment, the natural stone cover plate 200
has a singular central opening 202 large enough to allow a standard
outlet 206 (or switch) to fit through, as shown (embodying herein
wherein such product comprises at least one aperture for electrical
terminals). Preferably, the central opening 202 has a recessed
portion 204 on the back face 205 (which is an unpolished face)
surrounding the exterior perimeter of the central opening 202, as
shown. The recessed portion 204 may be substantially rectangular;
however, it is most preferable to provide a triangular portion 209
for the upper and lower screw attachments 210 and 212 respectively,
on the outlet 206, as shown. Typically, the outlet 206 has a front
face 214 and a recess 216 that allows a cover plate to set flush
with the front face 214, as shown (see FIG. 17). Most preferably,
the recess portion 204 is cut into the natural stone cover plate 200
such that recess portion 204 provides that the outlet 206 will fit
onto the natural stone cover plate 200 and in the recess portion 204
such that the front face 214 is about flush with the front face 218
of the natural stone cover plate 200, as shown (the front face being
typically and preferably a polished stone face). The above described
arrangement embodies herein reducing such thickness of such plate
adjacent such aperture, to form a recess, in such manner that, if
such cover plate is attached over a particular such electrical
service device having a particular outer contour, an outer surface
of such cover plate is substantially aligned with an outer surface
of such electrical service device.
Preferably, the natural stone cover plate 200 also includes two
screw-apertures 208, preferably located to align with the most
standard screw holes of an outlet 206 (as previously described
above). Under appropriate circumstances, other arrangements may
suffice. For example, the outlets and cover plates come in a variety
of sizes and combinations. Since the preferred embodiment is
custom-made to fit the users requirements, it is noted that the
description herein may be modified to accommodate other styles and
types of outlets and switches.
Preferably, the natural stone cover plate 200 also includes two
screw recesses 220 to accommodate the screws 222 typically used to
attach an outlet 206 to an electrical wiring box 224, typically
attached to a wall stud within a wall. Providing the recesses 220
reduces the possibilities of cracking the natural stone cover plate
200 when tightening the screws 226 used to attach the natural stone
cover plate 200 to the outlet 206, as shown.
FIG. 18 is a perspective view of a blank natural stone plate 230
illustrating a first step in a method of making the natural stone
cover plate 200 of FIG. 15 according to another preferred embodiment
of the present invention. Preferably, the above-described method
illustrated in FIGS. 3 through 5 is utilized to provide a blank
natural stone plate 230.
FIG. 19 is a perspective view of another step in the method of
making the natural stone cover plate 200 of FIG. 15 illustrating a
method of reducing the thickness of the stone utilizing horizontal
grinding of the blank plate.
Preferably, in this embodiment, the method used to reduce the
thickness of the stone is augmented utilizing a surface grinding
machine 232 in lieu of, or in addition to, the vertical sawing of
FIG. 5. Applicant has found that use of a vacuum assisted chuck 234
greatly enhances the efficient use of such a surface grinding
application and has designed a specific such vacuum assisted chuck
234 that will be further described in FIG. 31 and FIG. 32.
Preferably, the vacuum assisted chuck 234 is designed to hold four
blank natural stone plates 230 at a time. Under appropriate
circumstances, other arrangements may suffice.
Preferably, four such blank natural stone plates 230 are placed on
the vacuum assisted chuck 234 (or other such holding device).
Typically, such a surface grinding machine 232 has a slidable table
236 which moves in three axis: left/right, up/down and in/out such
that the surface of the material to be reduced (in this case the
blank natural stone plates 230) may be moved in the three axis
underneath the grinding wheel 238. It is also preferable that the
grinding machine 232 includes a magnetic chuck. Preferably, the
magnetic chuck is used to hold the vacuum assisted chuck on the
slidable table 236. Preferably, the grinding wheel 238 has diamond
grit for removing stone. Such grinding machines 232 may be
hand-operated or computer-controlled. Furthermore, such grinding
machines 232 may be water-assisted (for cooling) during the grinding
operation or dry (air cooled). Most preferably, a water-assisted
grinding machine is used to grind (cut) the blank natural stone
plate 230 along with the diamond-grit grinding wheel 238 (embodying
herein wherein reducing the thickness of each such blank to a
desired thickness for a desired such cover plate comprises, at least
partially, grinding a rear unfinished surface of such plate, using a
surface grinder, to achieve such desired thickness). Preferably, the
vacuum assisted chuck 234 is connected to an outdoor shop vacuum by
a hose 240, as shown. Preferably, the vacuum assisted chuck 234
holds the blank natural stone plates 230 firmly in place during
grinding of the blank natural stone plates 230 to the desired
thickness (embodying herein wherein such step of surface grinding
comprises use of a vacuum-assisted chuck). Preferably, the blank
natural stone plates 230 are placed face down (the blank natural
stone plates 230 have a polished shiny front face).
FIG. 20 is a perspective view of another step in the method of
making the natural stone cover plate 200 of FIG. 15 illustrating
drilling of a center pilot hole 242. Preferably, after grinding, the
now properly sized-to-thickness plate 244 is placed into a jig 246
(as stated earlier, a device used to maintain mechanically the
correct positional relationship between a piece of work and the tool
or between parts of work during assembly) which is specifically
sized to hold the plate 244, as shown. Preferably, the jig 246 is
then clamped onto a drill press or in a position to be drilled, as
shown. Preferably, a drill 248 and drill bit 250 are used, in
well-known ways, to drill a pilot hole (a term commonly used in the
art to describe a starter opening; used herein for placement of a
router cutting bit). Preferably, the drill 248 is a standard
electric drill about one-half horsepower. Preferably, the drill bit
250 is a diamond core drill bit, preferably about three-quarter inch
in diameter for use with a one-half inch to three-quarter inch
diameter diamond core router bit. Under appropriate circumstances,
other drill 248 horsepower or drill bit 250 diameters may suffice.
FIG. 21 is a perspective view of yet another step in the method of
making the natural stone cover plate 200 of FIG. 15 illustrating use
of a routing jig 252. Preferably, the plate 244 with the pilot hole
242 is now placed into a routing jig 252, as shown. Preferably, the
routing jig 252 is clamped or held in placed such that it will not
move during the routing operation 254. FIG. 22 is a perspective view
of yet another step, the routing operation 254, in the method of
making the natural stone cover plate 200 of FIG. 15 illustrating use
of a router 256. FIG. 23 is a sectional view through section 23--23
of FIG. 22. Preferably, a router 256 with an attached router bit 258
is used, in well-known ways by those knowledgeable in the art, to
cut recess 204 into the plate 244, as shown. Preferably, about
three-sixteenths of an inch of material is milled away by the router
256 for the recess 204 (when a three-eighths overall plate thickness
is used). Such a jig 252 commonly utilizes the inner perimeter 258
of the jig 252 to guide the router base 260 as a user 262 moves the
router base 260 around the inner perimeter 264 of the jig 252, as
shown. As the router base 260 is moved around the inner perimeter
264, the router bit 258 cuts a pattern in the plate 244 (embodying
herein routing such at least one such recess in such rear surface;
and embodying herein machining out such at least one hole to form at
least one larger aperture through such plate adapted to expose such
at least one electrical service device for use). Under appropriate
circumstances, other jig 252 arrangements may suffice as long as the
cutting function is maintained.
Preferably, the router 256 is at least a one-half horsepower
electric router utilizing a one-half inch chuck. Preferably, the
router bit is a three-quarter inch diamond tipped flush-trim router
bit (with or without a guide bearing) utilizing a one-half inch
shank. Under appropriate circumstances, other horsepower, bit types
or sizes may suffice.
FIG. 24 is a perspective view of another step in the method of
making the natural stone cover plate 200 of FIG. 15 illustrating
drilling of screw holes 208. Preferably, the cover plate 266 having
a recess on the back face 205 (the unpolished face) is now placed
into another drilling jig front face 268 (the polished face) facing
up. Preferably, a pair of drills 270 and drill bits 272 are set up
to be adjusted to the preferred screw spacing for a typical cover
plate (about four inches) attachment to an electrical device (for
example outlet 206) and used to cut through the front face 205 of
the cover plate 266 to create screw holes 208. Preferably, both
drills 270 are one-half horsepower electric drills each respective
drill preferably using a one-eighth inch diameter diamond core drill
bit 272. Preferably, a second drill bit is then inserted into each
respective drill to create a recess into which the screw head 276
(illustrated in FIG. 17) may fit. Preferably, the second drill bit
is a diamond chamfer bit. Preferably, an approximately
one-quarter-inch diameter recess is created for the screw head 276.
Under appropriate circumstances, other arrangements to drill and
recess the screw holes 208 may suffice. For example, those
knowledgeable in such art may choose to use a singular drill or a
set of drills for drilling and recessing the screw holes 208.
FIG. 25 is a perspective view of yet another step in the method of
making the natural stone cover plate 200 of FIG. 15 illustrating
drilling of screw recesses 220 and use of another jig 282.
Preferably, the cover plate 280 (now with screw holes 208) is turned
rear face 205 facing upward in jig 282, as shown. Preferably, an
upper recess 284 and lower recess 286 is formed to provide a space
for the screws 222 (shown in FIG. 17) which are used to attach the
outlet (or other electrical device) to an electrical wiring box 224,
as shown. Preferably, a Dremel.RTM. tool 290 is used to create the
recesses 220, as shown. Under appropriate circumstances, other tools
may suffice.
FIG. 26 is a perspective view of another step in the method of
making the natural stone cover plate 200 of FIG. 15 illustrating
another routing step 292. FIG. 27 is a sectional view through
section 27--27 of FIG. 26. Preferably, step 292 is utilized to cut
out the central opening 202 (embodying herein wherein such recess is
formed by routing). Preferably, an electric router 294 including a
flush trim router bit 296 having a guide bearing 298 is used, as
shown. Preferably, the guide bearing 298 or tracing bushing (not
shown) is moved around the inner perimeter 300 of a lower plate 302
having an opening 304, as shown. Use of such a jig 282 is well known
by those knowledgeable in the art of using a router.
Preferably, the router 294 is at least a one-half horsepower
electric router utilizing a one-half inch chuck. Preferably, the
router bit 296 is a three-quarter inch diamond tipped flush-trim
router bit with a guide bearing utilizing a one-half inch shank.
Under appropriate circumstances, other horsepower, bit types or
sizes may suffice.
FIG. 28 is a side view, partially in section, of another step 310 in
the method of making the natural stone cover plate 200 of FIG. 15
illustrating use of a typical table saw 312 for beveling the edges
of the cover plate. Preferably, the natural stone cover plate 200
has a beveled edge 314 or rounded edge 316 along the outer perimeter
318 of the plate 320, as shown. A user may order either or a
combination of both. Preferably, the outer perimeter 318 of the
plate is beveled using a jig 322 that will hold the plate 320 at the
desired angle as it is pushed across a saw blade 324 of a typical
table saw 312, as shown. Preferably, the plate 320 is placed front
face 218 face up and pushed along the saw blade 324. Under
appropriate circumstances, other arrangements may suffice.
FIG. 29 is a side view, partially in section, of a step in the
method of making the natural stone cover plate 200 of FIG. 15
illustrating use of a saw for rounding the edges of the cover plate
320. Preferably, as described above a jig 330 is used to hold the
cover plate 320 at the desired angle as it is pushed across a radius
cutter saw blade 322 of a typical table saw 312 to create a rounded
edge 316, as shown. Preferably, the rear face 218 is placed facing
up when cutting the rounded edges 316, as shown. Under appropriate
circumstances, other arrangements may suffice, however, applicant
has discovered the preferred method reduces chipping of the stone.
It is noted that both a rounded edge 316 and the beveled edge 314
may be used together or separate on the same cover plate.
FIG. 30 is a perspective view of a final step in the method of
making the natural stone cover plate 200 of FIG. 15 illustrating a
polishing means. The final step in the manufacturing method is to
polish or buff the entire cover plate 340, as shown. Preferably, a
buffer pad 342 is used with a buffing wheel 344. Such machines are
common.
It is noted that polishing of natural stone surfaces varies with the
stone and desired degree of polish. Those knowledgeable in such art
will, without undue experimentation, easily derive appropriate
buffing grit and polishing times to achieve the desired polish.
Applicant has found a buffer with a one-third to three horsepower
motor is preferable. Further, Applicant prefers utilizing a buffing
wheel speed of between about 400 and 3400 RPM in conjunction with
buffing pads of between about 100 and 8500 grit, to achieve a
preferable polish on most natural stone. However, as the polish is
custom and selected by the user, other arrangements may be selected
without detracting from the intended result (for example, those
described in the alternate embodiments above).
FIG. 31 is a perspective view of a vacuum-assisted chuck 234 used to
hold the blank cover plates 230 during the grinding process. FIG. 32
is an exploded perspective view of the vacuum-assisted chuck 234 of
FIG. 31.
Preferably, the vacuum-assisted chuck 234 is designed to hold four
blank natural stone plates 230 at a time. Preferably, the blank
natural stone plates 230 are placed onto the chuck 234 and the
vacuum source (a 16 gallon wet/dry shop vacuum is preferred) is
turned on wherein the blank natural stone plates 230 are tightly
held on the chuck 234 and maybe reduced in thickness to the desired
size. Applicant has found that four plates at a time is most
efficient for the grinding process. Preferably, the vacuum-assisted
chuck 234 is made of metal such that a magnetic chuck, which is
preferably used on the grinding machine, will be able to
magnetically hold the vacuum-assisted chuck 234 when placed on a
slidable table 236 (illustrated in FIG. 19). In a preferred
embodiment, the vacuum-assisted chuck 234 is made of steel. Most
preferably, corrosion-resistant steel is used (such as stainless
steel). Preferably, a base 348 is created using a steel U-channel
350, preferably C-5 steel U-channel having a wall thickness of about
five-sixteenths of an inch, a width W of about five inches (to
accommodate a plate length of about four and five-eighths inches)
and a side height H of about one and three-quarters inches is used.
Preferably, the C-channel is cut to a length L of about thirteen
inches (to accommodate four plates wide, each respective plate
having a width of about three and an eighth inches). Under
appropriate circumstances, other thickness and dimensions may
suffice. Preferably, a solid steel plate 352, preferably having a
wall thickness of about five-sixteenths of an inch, is attached to
one end 354 of the C-channel, as shown. Preferably, the solid steel
plate 352 is weldably attached to end 354. Preferably, a solid steel
plate 356, preferably having a wall thickness of about
five-sixteenths of an inch, with a central aperture 358 is attached
to the other end 360 of the C-channel, as shown. Preferably, the
central aperture 358 has a diameter of about three-quarters of an
inch (or sized to accommodate whatever sized pipe attachment will be
used). Preferably, the steel plate 356 is weldably attached to end
360. Preferably, a three-quarters inch diameter pipe 359 is then
weldably attached to the solid steel plate 356 aligned and adjacent
with the central aperture 358, as shown. Under appropriate
circumstances, other sizes and dimensions or attachment arrangements
may suffice.
Preferably, the top 362 of the vacuum-assisted chuck 230 is made
using a solid steel plate 364, preferably having a wall thickness of
about five-sixteenths of an inch, which is machined in the following
described manner. Preferably, one-quarter inch diameter apertures
are drilled completely through the solid steel plate 364 beginning
with a central group of apertures 366 placed along the central
longitudinal axis of the solid steel plate 364 approximately one and
one-half inches apart, as shown. Preferably, another group of
one-quarter inch diameter apertures 368 is drilled on each
transverse side of the central apertures 366, also about one and
one-half inches apart, both from the central apertures 366 and from
each respective adjacent aperture 368, as shown. The above-described
arrangement embodies herein a vacuum-assisted chuck comprising at
least one substantially-hollow boxlike body wherein: at least one
upper surface of such chuck comprises a set of apertures structured
and arranged to hold, using a vacuum created from a wet/dry shop
vacuum device, at least one stony custom cover plate during a
surface grinding step.
Preferably, there is a solid steel border 370 around the perimeter
of the top 362 about one-quarter to one-half inch wide, as shown.
Under appropriate circumstances, other dimensions or arrangements
may suffice. For example, if another sized cover plate or quantity
is desired, one may utilize a manufacturing method of such blank
cover plates 230 wherein it may be preferable to change the
above-described dimensions.
Preferably, after the apertures 366 and 368 are drilled, grooves 372
are formed adjoining all the apertures 366 and 368, as shown.
Preferably, the grooves 372 are made by using a right-angle grinder
with a metal-cutting blade. Under appropriate circumstances, other
tools may be utilized to form the grooves 372. Preferably, the
grooves 372 assist in providing a uniform suction on the blank cover
plates 230. Preferably, the top 362 is then weldably attached to the
base 348, as shown. The above-described arrangement embodies herein
a set of grooves connecting all of such set of apertures on such at
least one upper surface of such chuck.
Preferably, a one-eighth inch thick solid plastic stop 380 is
adhesively placed on the top and end of the vacuum-assisted chuck
230, as shown to act as an aligning stop when placing the cover
plates onto the vacuum-assisted chuck 230. Under appropriate
circumstances, other arrangements may suffice. For example small
welds could be used for a stop.
The vacuum-assisted chuck 230 is now ready to be connected to a
vacuum source. Preferably, a typical sixteen-gallon wet/dry shop
vacuum is used. Such a shop vacuum is readily available at most
hardware stores. Preferably, the hose to the shop vacuum is simply
attached to the pipe 359 using a clamp or even duct tape. Under
appropriate circumstances, other types of vacuum may be used,
however, Applicant prefers an inexpensive arrangement.
It is once again noted that the manufacturing techniques described
herein may be critical because of the ease of breakage of natural
stone and stony materials.
It is noted that, under appropriate circumstances, the methods and
products disclosed herein may be applied to other appropriate
brittle materials.
Although applicant has described applicant's preferred embodiments
of this invention, it will be understood that the broadest scope of
this invention includes such modifications as diverse shapes and
sizes and materials. Such scope is limited only by the below claims
as read in connection with the above specification.
Further, many other advantages of applicant's invention will be
apparent to those skilled in the art from the above descriptions and
the below claims.
* * * * *
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