This invention relates to woodworking tools. Specifically, this invention relates to an articulated iron cap for a hand plane.
Hand planes have been used for hundreds of years to smooth the surface of wood. A hand plane works when a woodworker pushes or pulls the plane across the surface of the wood which allows the sharp blade or the plane iron to engage the wood and shear off a thin layer of wood, thereby smoothing the wood surface.
In order for the iron 28 to be of use, it must be sharpened. The sharpened area on an iron 28 is called the bevel 29. Most prior art hand planes are designed in one of two ways. They either have the iron bevel up, or the bevel down in relation to the sole 14 of the plane. Typically planes that have a down bevel are similar to the design shown in the hand plane assembly 10. On the other hand, common bevel up irons are used in a different style of hand plane (not shown) which do not have the frog. Instead, the iron 28 lays on an inclined surface on the inside of the base unit 12 without the aid of the frog 20. This allows a bevel up iron 28 to lie at a much more reclined angle inside the base unit 12 of the plane.
A prior art bevel up type iron 28 plane which is not shown, is commonly known to one skilled in the art. A bevel up iron 28 allows a user with the much more inclined angle on the iron 28 to use the plane in more difficult types of wood. The sharper attack angle allows the plane to cut woods with more difficult grain. Thus, each type of plane, bevel up or bevel down, has its own specific purpose.
A cap iron 30 is used in conjunction with the iron 28 on bevel down type planes. The cap iron 30 is secured to the iron 28 by the use of a cap iron screw 36. This cap iron 30 acts as a chip breaker which helps to curl the cuttings cut by the iron 28 before they have a chance to split away from the larger working piece of wood. The end result is that the chip breaker part 38 on forward end of the cap iron 30 as seen in
Typically, most lever caps 32 are of solid construction cast metal with the only moving part as the lever 34. This allows for a solid lever action while pivoting at the fulcrum stud 26 to allow force on the cap iron 30 to hold it tight. However, other types of lever caps 32 have been developed. For example, U.S. Pat. No. 1,822,520 discloses a clamping lever assembly 40 which is seen in
One of the problems with existing planes is that frogless planes lack a chip breaker. This can cause a “lever-effect” of a shaving and wood can be “torn” out ahead of the cut. The result is an undesirable rough cut. Another problem with this type of assembly of the prior art, is that the pressure from the lever cap 32 or the clamping lever assembly 40 is applied to the cap iron behind the cutting edge of the iron 28. This allows the cutting edge of the iron 28 to vibrate and contributes to rough cuts. This creates opportunities for vibration and flex of the iron 28. This leads to chatter in thin cuts as the iron 28 loads and depends on the user to maintain a rigorous and forceful motion to keep the iron loaded during use. Every cutting edge, whether in wood or metal, needs a load (or bite) to work properly. With hand planes, the load occurs when the cutting edge first encounters the material to be cut. The edge of the blade or iron 28 deflects slightly and as long as there is significant forward motion of the plane, the iron 28 remains loaded and cuts the material.
The primary object of the present invention is to provide an improved plane iron cap.
It is a further object of this invention to allow the iron to be tensioned or loaded while locked in place.
It is a further object of this invention to create the ability to vary the depth of the cut while the iron is locked in place.
It is a further object of this invention to add mass and tension to the area of the iron that is unsupported in traditional planes therefore making the iron more rigid.
It is a still further object of the invention to create a plane which dramatically dampens vibration during use.
It is a further object of the invention to create a cap iron which also functions as a chip breaker.
It is a further object of the invention to eliminate the need to separate the iron from the chip breaker on the cap iron prior to sharpening.
It is a still further object of the invention to create a seal between the iron and the chip breaker which eliminates tuning of new planes and prevent chips from becoming lodged between the chip breaker and the iron.
It is a still further object of the current invention to allow bevel up planes to have the aid of a chip breaker.
It is a still further object of the invention to minimize grain lift when using the plane to plane wood.
It is a further object of the invention to allow the cap iron to seat throughout the entire lateral adjustment range of the iron.
It is a further object of the invention to allow the cap to seat against the iron regardless of the primary grind angle or bevel on the iron.
It is a still further object of the invention to add mass to the cutting edge of the iron to act as a vibration dampener.
It is a still further object of the invention to create a plane which can eliminate the use of a frog while still having a chip breaker.
It is a further object to move the flexing point of the iron from the fulcrum stud down closer to the cutting edge of the iron.
A further object is the provision of the articulated plane iron cap which is economical to manufacture, durable in use, and efficient in operation.
One or more of these or other objects of the invention will be apparent from the specification and claims that follow.
The foregoing objects may be achieved by creating a hand plane with a base unit configured for holding an iron wherein the base unit is comprised of a sole and a throat and the iron is configured with a beveled edge which can extend through the throat of the base unit and an articulated iron cap is used to position the iron through the base unit wherein the iron cap is configured to pre-load the iron and also to act as a chip breaker.
A further feature of the present invention involves an iron cap which has a pivoting dampner with an extendable pressure bar which traverses in and out of the dampner for engaging the iron and dampering vibration in the iron.
A further feature of the present invention involves a hand plane, wherein the iron is configured as either an up beveled iron or a down beveled iron.
A further feature of the present invention involves a hand plane, wherein the iron cap is pivotally mounted to the base unit.
Another feature of the present invention involves a hand plane, wherein the iron cap is further comprised of a two axis or a three axis chip breaker, and the chip breaker self-aligns with the grind angle on the iron.
A still further feature of the present invention is a hand plane wherein the chip breaker is further comprised of a button or a rib, which is configured so as to apply pressure against the iron to pre-load the iron.
A further feature of the present invention involves a hand plane, wherein the throat is configured as an adjustable throat.
A still further feature of the present invention involves a hand plane, wherein the chip breaker is further comprised of a button or a rib, which is configured so as to apply additional pressure directly behind the bevel to pre-load and dampen the iron.
The foregoing objects may also be achieved by creating an iron cap for a hand plane comprising a means for pivotally mounting to a hand plane, an articulating means for tensioning an iron in the hand plane, whereas the articulating means is further configured as a chip breaker.
A further feature of the present invention involves an iron cap for a hand plane wherein the iron cap is configured to mate to a bevel down iron or a bevel up iron.
A further feature of the present invention is an iron cap for a hand plane wherein the chip breaker is configured with a two or three dimensional axis for engaging the iron plane.
A further feature of the present invention involves the iron cap for a hand plane wherein the chip breaker is configured to pivot approximately perpendicular to the longitudinal axis of the hand plane so as to adjust to the angle, or pitch of the iron.
The foregoing objects may also be achieved by a hand plane configured to have a base unit with a sole and a throat, at least one handle attached to the base unit, a beveled iron for extending through the throat on the base unit and an iron cap, wherein the iron cap comprises a means for pivotally attaching to the base unit, a means for engaging the beveled iron, and an articulated chip breaker.
A further feature of the present invention involves a hand plane wherein the iron cap articulates relatively perpendicular to the longitudinal axis of the hand plane.
A further feature of the invention is a hand plane wherein the iron cap further comprises a nose piece, wherein the nose piece is configured to pivot so as to engage varying grind or bevel angles of the iron.
A further feature of the present invention involves a hand plane wherein the iron cap further comprises a button, wherein the button is configured to apply additional pressure on the iron.
A further feature of the present invention is a hand plane wherein the iron cap further comprises a raised rib, wherein the rib is configured to apply additional pressure to the iron.
A further feature of the invention is a hand plane wherein the iron cap further comprises a nose piece, wherein the nose piece is configured to pivot so as to engage tightly regardless of the varying grind or bevel angles of the iron, or manufacturing tolerances.
There are several words that need to be defined for the purpose of this invention. This invention is entitled an Articulated Iron Cap for a Hand Plane. The word articulated simply means that the iron cap has joints or segments and is capable of having rotating parts. Another word that needs to be defined is loading. This invention refers to loading of the plane iron. Loading simply means applying pressure against the iron so as to push the lower end of the iron down and back towards the rear of the throat of the base unit with pressure as much as or greater than the pressure that would be applied as the iron is driven into the wood in which it is to cut where the wood would be pushing against the lower edge or the cutting edge of the iron. The current invention allows for the iron to be pre-loaded with a force as much as or greater than the load force of standard hand planes, thereby significantly reducing any flexing, chatter or vibrating of the iron during use. The pre-loading of the iron in the current invention allows for a much smoother cut because the iron does not flex when it is driven into the wood that is being worked. In addition, this pre-loading force allows the depth of cut to be adjusted by adding more loading force to the iron by further tightening a tensioning bolt. In fact, the depth of cut can be finely adjusted up to approximately 0.003″ (0.0762 mm) in this manner.
Another word that needs defined is iron. Iron does not refer to the type of material or element in which the current invention is made of. Rather, iron is a term commonly known in the art for the blade or the cutting device which actually cuts the wood for a hand plane. Therefore, a cap iron (or iron cap) is a cap that simply goes over the top of the iron, which can be made of many different materials including steel, cast iron, brass, or other similar metals.
The invention is an articulated hand plane iron cap for use on a woodworking plane. One embodiment of the invention is shown in
This embodiment of the invention is constructed with a base unit 12 in which the underside of the base unit 12 is called the sole 14. An opening in the sole 14, is a throat 16. The throat 16 can be configured as an adjustable throat, as is common in the art. Attached to the base unit 12 is also one or more totes or handles 18. The totes 18 allow the user to grip the plane so they can push or pull the plane over the wood surface to be planed however, totes 18 are not necessary. The bevel up iron 28A rests on the depth adjuster 22 and a portion of the base unit 12 and extends through the throat 16. The iron 28A is held to the base unit 12 by the articulated iron cap assembly 60A. The articulated iron cap assembly 60A is constructed with an iron cap main body 64 which pivotally mounts to the base unit 12 by the iron cap assembly main pivots 74. These iron cap assembly main pivots 74 allow the articulated iron cap assembly to pivot back and forth along the iron cap assembly main pivot 74 axis.
When the tensioning bolt 62 is screwed into the iron cap main body 64, it applies pressure to the iron 28A. The articulating chip breaker 66A, which is pivotally attached to the iron cap main body 64, then moves downward after the articulated iron cap assembly 60A pivots about the iron cap assembly main pivot 74. Attached to the articulating chip breaker 66A is a nose piece 68. As the tensioning bolt 62 is screwed tighter into the iron cap main body 64, the nose piece 68 engages the iron 28A. The tighter the tensioning bolt 62 is tightened, the tighter the pressure that is held on the iron 28A. This pressure or loading allows the articulated iron cap assembly 60A to hold the iron 28A into the base unit 12 of the plane.
The articulated iron cap assembly 60A of the current invention allows a hand plane to have a chip breaker 66A without the use of a cap iron 30. This chip breaker 66A applies pressure at the very bottom end, near the cutting edge of the iron 28A. Putting pressure at the very bottom end directly on the iron 28A allows the articulated iron cap assembly 60A to hold the iron 28A extremely steady which reduces vibration on the iron 28A, which in turn creates a better cut with the plane. In addition, the articulating chip breaker 66A adds a large mass coupled directly near the cutting edge of the iron 28A which further reduces vibration of the iron 28A and additionally creates a smoother, more accurate, and better cut.
As seen in
As seen in
Another embodiment of the current invention is shown in
The embodiment of the invention shown in
The current invention allows the chip breaker 66A and 66B to be pivotally attached to the iron cap main body 64 and eliminates the need for a cap iron 30 of the prior art. Thus, sharpening of the iron 28A and 28B can be done without having to follow the extra step of removing a cap iron 30. In addition, having the extra mass of the chip breaker 66A and 66B applying pressure near the bottom cutting edge of the iron 28A and 28B allows extra mass to be added to the lower end of the iron 28A and 28B near the cutting edge which reduces vibration and creates a smoother, better cut of the wood being planed with less effort.
This invention refers to loading of the plane iron. Loading simply means applying pressure against the iron so as to push the lower end of the iron down and back towards the rear of the throat of the base unit with pressure similar to the pressure that would be applied as the iron is driven into the wood in which it is to cut where the wood would be pushing against the lower edge or the cutting edge of the iron. The current invention allows for the iron 28A or 28B to be pre-loaded to a force far greater than the load force of standard hand planes, thereby significantly reducing any flexing or vibrating of the iron 28A or 28B during use. The pre-loading of the iron 28A or 28B in the current invention allows for a much smoother cut because the iron 28A or 28B does not flex when it is driven into the wood that is being worked. In addition, this pre-loading force allows the depth of cut to be adjusted by adding more loading force to the iron 28A or 28B by further tightening the tensioning bolt 62. In fact, the depth of cut can be adjusted by approximately 0.003″ (0.0762 mm) in this manner.
Similarly,
The sound made by the preferred embodiment of the current invention during use is different from the sound made by traditional planes. The additional tension or loading on the iron 28A and 28B and the additional mass added near the bevel 29A and 29B edge changes the natural frequency of the plane. This in turn changes the pitch (sound) and contributes to a reduction in the iron resonating (vibrating). The result is that a reduction in force is needed to work the plane and the iron 29A and 29B stays sharp longer.
In the drawings and specification there has been set forth a preferred embodiment of the invention, and although specific terms are employed, these are used in a generic and descriptive sense only and not for purposes of limitation. Changes in the form and the proportion of parts as well as in the substitution of equivalents are contemplated as circumstance may suggest or render expedient without departing from the spirit or scope of the invention as further defined in the following claims.
This application is a Continuation-in-Part and claims priority under 35 U.S.C. § 119 of U.S. application Ser. No. 10/992,583 filed Nov. 18, 2004, which application is hereby incorporated by reference in its entirety.
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Number | Date | Country | |
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20060101654 A1 | May 2006 | US |
Number | Date | Country | |
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Parent | 10992583 | Nov 2004 | US |
Child | 11214385 | US |