Pocket hole drilling machine

Abstract

A pocket-hole drilling apparatus for drilling pocket-holes in a workpiece is disclosed. In one embodiment, an initiation switch actuates clamping the workpiece and the movement of a drilling module to cut a pocket-hole. The drilling module has a motor and a step-drill mounted thereon, which is slidably mounted on a guide module. The axis of the drilling module movement intersects work surface. In another embodiment, a movable fence provides the adjustability of pocket-hole depth. In yet another embodiment, two actuator tips are disposed in a fence to prevent the drilling of a pocket-hole through the sidewall of a workpiece. In still another embodiment, a short stroke clamping actuator is used to prevent human finger injury. In still another embodiment, a blower or an ejector pump is used to remove wood chips, wherein the blower is either attached to a drilling motor or to a separate blower motor; the ejector pump is mounted near the drill guide. In still another embodiment, two pocket-drills are slidably mounted on a block so as to drill two pocket-holes and to adjust pocket-hole spacing. In still another embodiment, a mounting structure is disposed either underneath or above the work surface to mount drilling module(s) so as to drill multiple pocket-holes into a wide workpiece at one setup. In still another embodiment, a drill guide forms a clearance for the cutting edges of the step-drill to minimize wear on the edges. In a further embodiment, an actuator provides both clamping and drilling movements, wherein the actuator is an electric motor or a hand lever.

What is claimed is: 
     
       1. An apparatus for drilling pocket-holes into a workpiece for use cooperatively with a step- drill, comprising:
 a body, said body having a planar work surface defining a plane; 
 a drilling module positioned below said work surface at an acute angle for cutting the pocket-hole, said drilling module having a motor for driving the step- drill, wherein said drilling module is movable in a drilling direction from a first position to a second position by an actuator, wherein the step-drill whereby the drill is below the work surface in a first position and at least a portion of the drill intersects said plane planar work surface in a second position; 
 a fence for positioning a workpiece, said fence mounted on said work surface at substantially a right angle with respect to said drilling direction to position a workpiece; and 
 at least one initiation switch disposed on said work surface and having a relationship with the said workpiece so as to cause the permit said actuator to move said drilling module when the workpiece urges actuates said switch. 
 
     
     
       2. The apparatus as claimed in of  claim 1 , wherein said initiation switch is disposed in said fence. 
     
     
       3. The apparatus as claimed in of  claim 2 , further comprising wherein said initiation switch includes two actuator tips having a relationship with said switch, wherein, the distance between said two actuator tips is sized to activate said switch when the workpiece is placed to urge actuate both said tips to prevent drilling the pocket-hole on the sidewall of the workpiece. 
     
     
       4. The apparatus as claimed in  claim 1 , wherein said switch is selected from the group consisting of a pneumatic switch, an electric contact switch, an electronic non-contact switch, and a mechanical switch. 
     
     
       5. An apparatus for drilling pocket-holes into a workpiece for use cooperatively with a step drill, comprising:
 a body, said body having a planar work surface defining a plane; 
 a drilling module for cutting the pocket-hole, said drilling module having a first motor for driving a step- drill, wherein said drilling module is and drill movable by an actuator in a drilling direction toward said work surface from a first position in which the drill is below the work surface to a second position by an actuator, wherein in which at least a portion of the step- drill intersects said plane work surface; 
 a guide module, said drilling module slidably mounted thereon, said drilling module engaging with respect to said guide module for movement in said drilling direction; and 
 an adjustable fence mounted on said work surface, said fence adjustable from above the work surface to position the workpiece so that the depth of drilling can be adjustable adjusted based on workpiece thickness. 
 
     
     
       6. The apparatus as claimed in of  claim 5 , further comprising at least one gauging structure mounted on said work surface, wherein said gauging structure is and movable with respect to said work surface to adjust the distance position of said fence from on said gauging structure work surface based on workpiece thickness. 
     
     
       7. The apparatus as claimed in of  claim 5 , further comprising a an initiation switch disposed in said fence so as to cause the said actuator to move said drilling module by said actuator when the workpiece urges actuates said switch. 
     
     
       8. The apparatus as claimed in of  claim 5 , further comprising a hollow output spindle disposed in said first motor so as to mount the step- drill. 
     
     
       9. The apparatus as claimed in of  claim 5 , further comprising a drill guide disposed within said guide module to guide the a step-drill, wherein having a first bore and a second bore formed coaxially in said drill guide, said first bore being sized to fit receive the step-drill and said second bore being positioned in a direction toward said plane work surface, wherein said second bore is formed by at least one of a substantial clearance with respect to the step-drill, and or a softer material than that of said first bore so as to minimize wear on edges of the step-drill. 
     
     
       10. The apparatus as claimed in  claim 5 , further comprising a drill guide disposed within said guide module to guide the step- drill, and a lateral coupling disposed between an output shaft of said first motor and the step- drill so as to compensate misalignment of said step- drill with respect to said drill guide. 
     
     
       11. The apparatus as claimed in of claim  5  9, further comprising a chip remover disposed in said body to remove wood chips generated from workpiece drilling by the step- drill, wherein at least one chip hole is formed within said guide module to connect to said chip remover. 
     
     
       12. The apparatus as claimed in  claim 11 , wherein the wood chips are removed by at least one of a blower, and an ejector pump, wherein said blower is attached to a motor, wherein said ejector pump is disposed in said chip remover and the supply of air to said ejector pump is selected from the group consisting of a blower attached to a motor, an exhaust air from an air motor and shop air. 
     
     
       13. The apparatus as claimed in  claim 5 , further comprising a clamp which is movable to secure the workpiece, wherein said actuator provides a first point, a second point and a third point, wherein the movement of said actuator from said first point to second point causes clamping the workpiece by said clamp and the movement of said actuator from said second point to third point causes said drilling module to move to cut the pocket-hole in the workpiece by said first motor. 
     
     
       14. The apparatus as claimed in of claim  13  5, further comprising a clamp above said work surface and the workpiece, said clamp downwardly movable to secure the workpiece on said work surface, and wherein said actuator is a hand operated lever which provides causes movement of said clamp and said drilling module. 
     
     
       15. The apparatus as claimed in of claim  13  5, wherein said actuator is a second electric motor which provides causes movement of said clamp and said drilling module, wherein and said first motor provides rotational torque to turn the step- drill. 
     
     
       16. The apparatus as claimed in of  claim 15 , further comprising an initiation switch disposed in said fence so as to turn power on said first and second motors power on when the workpiece urges actuates said initiation switch. 
     
     
       17. The apparatus as claimed in of claim  13  16, further comprising a reversing switch which turns said first motor power off when said drilling module urges actuates said reversing switch, wherein said first motor is driven by compressed air. 
     
     
       18. An apparatus for drilling pocket-holes into a workpiece for use cooperatively with a step- drill, comprising:
 a body, said body having a work surface defining a plane having a planar work surface; 
 a drilling module for cutting the pocket-hole, said drilling module having a motor for driving at least one step- drill, said drilling module movable in a drilling direction by an actuator, wherein the step- drill intersects said plane work surface; 
 a guide module having a guide block including at least one drill guide disposed within said guide block to guide the drill, said drilling module slidably mounted thereon, said drilling module slidably engaging with respect to said guide module in said drilling direction, and; 
 a mounting structure disposed in said body substantially at a right angle with respect to said drilling direction to mount for mounting a guide block of at least one said guide module; and 
 further comprising a rail mounted on said work surface substantially parallel to said mounting structure, wherein said rail is movable so that the depth of drilling is adjustable. 
 
     
     
       19. The apparatus as claimed in  claim 18 , further comprising at least two dowel drillers mounted on said body so as to drill dowel-holes parallel to said work surface on an edge-wall of the workpiece. 
     
     
       20. The apparatus as claimed in of  claim 18 , further comprising a rail mounted on said work surface substantially parallel to said mounting structure so as to position permitting the positioning of the workpiece thereto thereagainst, and a channel formed therein so as to mount at least one clamping actuator mounted thereon for securing the workpiece in position. 
     
     
       21. The apparatus as claimed in  claim 18 , further comprising a rail mounted on said work surface substantially parallel to said mounting structure, wherein said rail is movable so that the depth of drilling can be adjustable. 
     
     
       22. The apparatus as claimed in of  claim 18 , further comprising two drill holders each for mounting a step- drill in said drilling module and to slidably move in a sliding direction which is at substantially at a right angle with respect to said drilling direction, wherein said guide module has two guide adapters each for guiding the step- drill and to move in said sliding direction, wherein said two drill adapters are connected to be driven by said motor and are mounted so that the distance between the two step- drills can be adjusted. 
     
     
       23. The apparatus as claimed in  claim 22 , further comprising a rotatable screw that have oppositely pitched threads formed therein so as to engage and to move said two drill holders toward and away from each other in said sliding direction. 
     
     
       24. A clamp and drilling system for use with wood workpieces comprising:
 a substantially planar work surface on which the workpiece may be disposed, said surface having at least one opening;   a drilling module mounted below the work surface including a motor for driving a drill, the axis of the drill at an acute angle to the work surface, said drilling module movable from a first position to a second position at which the drill intersects the work surface through the opening in said work surface;   an actuator for moving said drilling module;   a fence mounted on said work surface at a substantially right angle to the drill axis, said fence adjustable on said work surface toward and away from said opening so as to permit setting the fence from above the work surface based on the thickness of the workpiece.   
     
     
       25. The system of claim 24 additionally comprising a clamping assembly mounted on said work surface and having a clamp pad positioned above the workpiece when the workpiece is in a position to be drilled, said clamping assembly activated by said actuator to cause said pad to contact the workpiece to secure it during the drilling operation. 
     
     
       26. The system of claim 25 additionally comprising a home switch mounted below said work surface and positioned so that when the drilling module is in the first position the home switch is off and the motor is deactivated and movement of said drilling module turns said home switch on and activates the motor. 
     
     
       27. The system of claim 26 wherein activation of said actuator immediately moves said drilling module causing activation of said home switch and said clamping assembly. 
     
     
       28. The system of claim 27 wherein said clamping assembly causes said pad to contact the workpiece no later than said drill contacts said workpiece. 
     
     
       29. The system of claim 28 wherein said home switch is activated prior to contact of the drill with the workpiece. 
     
     
       30. The system of claim 29 wherein initial movement of said drilling module and activation of said home switch is simultaneous. 
     
     
       31. An apparatus for drilling pocket-holes into a workpiece for use cooperatively with a drill, comprising:
 a body having a planar work surface   a drilling module for cutting the pocket-hole, said drilling module having a motor for driving at least one drill, said drilling module movable in a drilling direction by an actuator, wherein the drill intersects said work surface;   a guide module, said drilling module slidably mounted thereon further comprising:   two drill holders having two drill adapters each for mounting a drill in said drilling module and wherein the drill holders slidably move in a direction which is at substantially at a right angle with respect to said drilling direction, wherein said guide module has two guide adapters and two drill guides each slidably mounted within a guide block and intersecting the planar work surface for guiding the drill wherein said two drill adapters are connected to be driven by said motor and are mounted rotatably in said drill holders so that the distance between the two drills can be adjusted wherein the drill guides move laterally within the guide block to follow the movement of the drill holders.   
     
     
       32. A pocket hole drilling machine, comprising:
 a body having a frame;   a clamping module connected to the frame;   a guide module connected to the frame;   a drilling module slidably connected to the guide module;   an adjustable fence connected to the frame;   an actuation switch operatively connected to the fence.   
     
     
       33. The pocket hole drilling machine of claim 32 wherein the fence is adjustable from a side other than a bottom surface of the fence. 
     
     
       34. The pocket hole drilling machine of claim 32 further comprising gauging structure connected to the body and operatively associated with the adjustable fence. 
     
     
       35. The pocket hole drilling machine of claim 32 further comprising a sensor operatively connected to the body such that when activated the drilling module stops. 
     
     
       36. The pocket hole drilling machine of claim 32 further comprising a sensor operatively connected to the body such that when activated the drilling module reverses. 
     
     
       37. The pocket hole drilling machine of claim 32 further comprising a chip hole connected to the guide module. 
     
     
       38. The pocket hole drilling machine of claim 32 wherein activation of the actuation switch simultaneously actuates the clamping module and the drilling module. 
     
     
       39. A pocket hole drilling machine, comprising:
 a body having a frame;   a clamping module connected to the frame   a guide module connected to the frame;   a drilling module extending from a first end to a second end in a drilling direction slidably connected to the guide module;   an adjustable fence connected to the frame;   a sensor operatively connected to the second end of the drilling module such that when activated the drilling module stops.   
     
     
       40. A dual drilling module for a pocket hole drilling machine, comprising:
 a drilling module having a first drill holder and a second drill holder positioned in parallel spaced alignment;   an adjustment member operatively connected to the first drill holder and the second drill holder such that when actuated the distance between the first drill holder and second drill holder is adjusted and two drill guides and guide adapters each slidably mounted within a guide block and intersecting a planar work surface for guiding a drill move laterally within the guide block to follow the movement of the drill holders.   
     
     
       41. The dual drilling module for a pocket hole drilling machine of claim 40 further comprising a motor operatively connected to the first drill holder and the second drill holder. 
     
     
       42. The dual drilling module for a pocket hole drilling machine of claim 40 further comprising a first driven pulley connected to the first drill holder and a second driven pulley connected to the second drill holder. 
     
     
       43. The dual drilling module for a pocket hole drilling machine of claim 40 wherein the adjustment member has a knob. 
     
     
       44. The dual drilling module for a pocket hole drilling machine of claim 40 wherein the adjustment member has a screw. 
     
     
       45. A pocket hole drilling machine, comprising:
 a body having a frame;   a clamping module connected to the frame;   a guide module connected to the frame;   a drilling module slidably connected to the guide module which slides in a drilling direction;   an adjustable fence connected to the frame;   a mounting structure positioned within the body and extending in a generally perpendicular direction to the drilling direction and disposed laterally within the frame such that a plurality of guide modules are mounted to and are slidably and laterally positioned on the mounting structure.   
     
     
       46. The pocket hole drilling machine of claim 45 wherein the mounting structure is a rail. 
     
     
       47. The pocket hole drilling machine of claim 45 wherein the mounting structure extends upwardly from a bottom of the body.