This invention relates to a cutting tool for cutting sheets of building materials, for example laminate, at a range of angles from vertical and/or horizontal.
Discussion of Related Art
Users cut building materials, such as baseboards and crown molding, with a beveled or mitered cut in order to fit in or around corners.
The present invention provides a portable, non-power operated cutting tool for cutting sheets of building materials at a range of angles in both a vertical and horizontal direction without splintering or cracking. The present invention also allows for fine adjustment of the cutting angle by pivoting a support surface up or down to change the angle of the cut to allow abutting materials to properly align.
According to an embodiment of this invention, the cutting tool includes a cutting platform that includes an axle that allows both a base and a table support surface to be pivotally connected to the cutting platform. This design allows for rotational adjustment of the cutting platform, the base, and the table support surface relative to one another. Preferably, large angular adjustments are provided by moving the cutting platform relative to the base and locking the cutting platform in place. Small, compensating angles are provided by moving the table support surface relative to the base and locking the table support surface in place. The locking mechanism is preferably easily releasable, allowing the cutting tool of this invention to be easily and repeatedly set to cut a plurality of different angles.
The cutting platform of this invention preferably includes a cutting platform base with a pair of supports extending vertically from the cutting platform base. The supports are preferably positioned on either side of the cutting platform with a beam and a cam positioned to rotate between the supports. A blade holder and a blade are positioned under and in contact with the cam and designed to move along the supports of the cutting platform. To maintain a straight path of travel, each edge of the blade holder at least partially surrounds a respective support. The blade holder and the blade are moveable between an open position and a closed, cutting position, by rotating the cam. In the open position, the cam contacts the blade holder at a relatively small radius so that as the cam rotates, the blade holder contacts the cam at a gradually increasing radius until the blade holder and the blade are forced downward contacting a blade stop in the cutting platform base. For ease of operation, the blade holder and blade are biased into the open position with springs positioned under the blade holder and preferably with one spring surrounding each of the supports.
In a preferred embodiment, a handle is connected to the beam to assist in rotating the cam. The handle may adjustable, allowing for the handle to move through a full range of motion, from the open position to the closed position, for all angled cuts.
As discussed above, the cutting tool of this invention includes a device for temporarily locking the cutting platform at an angle to the base. In one embodiment, this device comprises a plate secured to an end of the axle and a latch pivotally mounted to the base. The plate includes a plurality of slots positioned along an outer edge, each slot used to set the cutting platform at an angle to the base. The latch engages with the slot to prevent further rotation of the axle. As the cutting platform and, in turn, the plate rotates, each slot also moves in and out of proximity with the latch mounted to the base. When a desired angle of the cutting platform is reached, the latch engages the respective slot in the plate to temporarily lock the cutting platform at a desired angle to the base. In a preferred embodiment, the plate includes at least four slots allowing the cutting platform to set at a right angle (marked as zero in the figures) to the base, at a 22.5° angle, at a 30° angle, and at a 45° angle to the base. However, it should be understood that the cutting tool of this invention is not limited to four slot or the identified angles and may comprise any number of slots defining any range of angles.
As discussed above, the cutting tool of this invention also includes a device for temporarily locking the table support surface at an angle to the base. In one embodiment, the table support surface includes a rack mounted on a bottom side (opposite side from the side that supports the material being cut). In this embodiment, the rack includes a plurality of grooves, each groove used to set the table surface at a fine angle to the base. For example, each groove may be used to set a 1° change of angle of the table support surface to the base. To temporarily hold the table in position, a releasable plunger is mounted to the base. The releasable plunger connector engages one of the plurality of grooves to lock the table surface at the fine angle to the base. In one embodiment, the rack and releasable plunger may be used to set the angle at +2°, +1°, 0, −1°, and −2°. However, the cutting tool of this invention is not limited to the identified angles and other angles may be selected.
As the cutting platform, the base, and the table support surface all rotate relative to one another, it is preferred that the blade moves in a plane that is co-planar with a centerline of the axle and the blade contacts a blade stop, in the cutting platform base, along a line that is collinear with the axis of rotation of the axle. This alignment prevents unintended movement of any of the cutting platform, the base, or the table support surface as the blade completes the cutting motion, preventing splintering and/or cracking of the material being cut.
According to a preferred embodiment of this invention, the base further includes a guide rail for aligning the building material to the blade. The guide rail is adjustable, allowing the building material to set at a range of angles to the blade in a horizontal plane.
These and other objects and features of this invention will be better understood from the following detailed description taken in conjunction with the drawings, wherein:
A cutting tool 10 of this invention is preferably used to cut building materials 100, such as laminate, in a predictable and straight fashion without splintering, cracking or similar problems that may arise from such cuts. As used herein, “building material” refers to a sheet or plank of building material, such as baseboards, crown molding, chair rail molding, wood flooring, laminate flooring, composite flooring, vinyl flooring, vinyl siding, vinyl composition tile, dimensional lumber or similar materials, including, but not limited to, one or more combinations of wood, fiber, vinyl, concrete, rubber, plastic and/or other materials that may or may not include a laminated layer.
The cutting tool 10 is preferably capable of cutting building materials 100 at a plurality of angles to a table surface 12 including, but not limited to, 0° (right), 22.5°, 30°, and 45° angles. However, it should be understood that the cutting tool 10 of this invention is not limited to the listed angles and may be used to cut other angles. In a preferred embodiment, the cutting tool of this invention allows for an angle of a table surface to be adjusted slightly, for example by 1 or 2 degrees up or down, to change a cutting angle of the cutting tool 10 in order to compensate for misaligned materials, for example misaligned baseboards. The cutting tool 10 of this invention is also capable of cutting building materials at a range of angles in a horizontal plane, with a guide rail 28 set perpendicular to the blade or at a range of angles including 22.5°, 30°, 45° and/or other angles. The vertical adjustment allows the cutting tool 10 to cut materials to, for example, fit around or in corners of a room and the horizontal adjustment allows the cutting tool 10 to cut materials to, for example to fit around window or door frames.
As shown in
In an embodiment of the invention, the base 14 comprises a rectangular base that provides stability for the cutting tool 10, however the base 14 is not limited to this shape and may comprise any shape that provides stable support for the cutting tool 10. The base 14 may be formed of steel, aluminum or another material with durable qualities capable of withstanding the force required to cut the building materials. In this embodiment, the base 14 also includes a plurality of wheels for moving the tool 10.
In an embodiment of this invention, the table surface 12 is connected to at least one of the cutting platform 16 or the base 14 and supports the building material 100 to be cut. The table surface 12 preferably includes a textured or a high friction, non-slip surface that prevents the building material from slipping or moving during the cutting process. The table surface 12 is preferably made of lightweight and durable materials, such as plastic, rubber, metal and/or composite materials, but may be made of any material capable of supporting the building materials and withstanding the cutting force generated by the cutting tool 10. The base 14 and table surface 12 are preferably sized to accommodate standard sizes of materials, such as a baseboard, and may correspond in width to such material.
The cutting tool 10 preferably further includes a guide rail 28 positioned on the table surface 12. The guide rail 28 can be used to align the building material at a range of angles, on a horizontal plane, to the blade 20. In the embodiment shown in
As discussed above, the cutting platform 16 is connected to the base 14 with a pivotable connection allowing the cutting platform 16 to be set at a plurality of angles relative to the base 14 allowing the blade 20 to cut at a plurality of angles. For example,
The cutting platform 16 preferably includes a cutting platform base 54, a blade stop 56, a pair of supports 58 extending from the cutting platform base 54, a beam 64 extending between the pair of supports 38, and a cam 66 mounted to the beam. The cam 66 further includes a cam edge 68 with at least two radii and preferably with a gradually increasing radius. The cutting platform 16 is preferably manufactured of steel but may comprise any material or materials capable of withstanding the force required to push the blade 20 through the building material 12.
As best shown in
In a preferred embodiment, this invention includes the handle 22 attached to the beam 50 to assist a user to rotate the beam 50 and the cam 66. In a preferred embodiment, the beam 50 includes a plurality of connections 70. The plurality of connections 70 allows the handle 22 to be set in at least two positions to compensate for the angle of the cutting platform 16, allowing the handle 22 to rotate fully from the open position to the closed position and to prevent the handle 22 from contacting the base 14. In an alternative embodiment, the handle may not include the adjustable connection and the attachment can be formed in various ways including, but not limited to, a threaded connection, a welded connection or an integral connection with the beam 50. The handle 22 preferably further includes a hand grip for the user to manually grab or engage. In an alternative embodiment, the handle 22 may be extendible to provide a longer lever for cutting the material.
As shown in the figures, the blade holder 18 and the blade 20 are positioned between the pair of supports 58, where the pair of supports act as guides for the blade holder 18 to maintain a generally straight path as the blade holder 18 moves from the open position to the closed position. The blade holder 18 may be formed of a material such as steel or similar rigid material. The blade 20 is preferably formed of steel or another material capable of repeatedly cutting all thicknesses and compositions of materials. In a preferred embodiment, the blade 20 is attached to the blade holder 18 with a threaded connection. With this arrangement, the blade 20 can be removed from the blade holder for repairs, sharpening and to select a specialty blade for any type of material. In an alternative embodiment, the blade 20 can be integrally formed with the blade holder 18.
As best shown in
According to a preferred embodiment, the blade holder 18 and blade 20 are biased upward into the open position by a spring 72. As shown in the figures, the spring 72 is positioned between the cutting platform 16 and the blade holder 18. In this embodiment, each spring 72 wraps around the support 58. In an alternative embodiment, the spring 72 may not wrap around the support 58. As the blade holder 18 travels downward, the spring 72 is compressed to further urge a uniform cut of the blade 20 through the material to be cut. The strength and configuration of the spring 72 may be adjusted depending on the desired application.
As discussed above, the table surface 12, the base 14, and the cutting platform 16 preferably all rotate about the same axis of rotation. In one embodiment of this invention, as best shown in
The cutting tool 10 of this invention preferably includes a device for locking a position of the cutting platform 16 relative to the base 14. In a preferred embodiment, the cutting tool 10 includes a plate 34 rigidly connected to an end of the axle 30 and a latch 44 mounted to the base 14. The latch 44 preferably moves to engage the plate 34 to lock the position of the cutting platform 16 relative to the base 14. As best shown in
As discussed in the background, sometimes, for example when there is an imperfection in the underlying walls that the building materials 100 are joined to, a user will adjust an angle of the cut by a small amount to allow a pair of abutting pieces to properly join. The cutting tool 10 of this invention allows for slight adjustment of the cutting angle by changing an angle of the table surface 12 relative to at least one of the base 14 and the cutting platform 16. As best shown in
Preferably, the table surface 12 is connected to the cutting tool at the axle 30, as discussed above, and to the base 14 with an adjustable, lockable connection allowing the table surface 12 to be set at plurality of angles relative to the cutting platform 16. In one embodiment, as shown in
In a preferred embodiment, the table surface 12 may include an aperature 78 to assist in lowering or raising the table surface 12. In other embodiments of this invention, the table surface angle may be adjusted using another type of mechanism.
In a preferred embodiment, as shown in the cross-sectional view of
As discussed above, the table surface 12, the base 14, and the cutting platform 16 preferably all rotate about the same axis of rotation. In a preferred embodiment, as shown in
In operation, a user of the cutting tool 10 of this invention selects a desired angle of cut, for example right, 22.5°, 30°, and 45°, and releases the latch 44 from the slot 42 and rotates the cutting platform 16 to the selected angle relative to the base 14. The latch 44 is pivoted into the selected slot 42 locking the cutting tool 10 in the selected angle. The user then determines if the selected angle needs to be adjusted slightly up or down. If so, the releaseable plunger connector 76 is pulled, disengaging the plunger from the rack 74. The table surface 12 is pivoted to the desired adjustment angle and the releaseable plunger connector 76 is released, reengaging with the rack 74, locking the table surface 12 relative to the base 14. The cutting tool 10 of this invention starts in the open position. In the open position, the spring 66 biases the blade holder 18 and the blade 20 upward and the cam 66 contacts the blade holder 18 at a relatively small radius, providing an opening between the blade 20 and the cutting platform base 54. The material 100 to be cut is placed onto the table surface 12 and through the opening formed between the blade 18 and the cutting platform 16. To cut the material 100, the handle 22 is lowered to rotate the cam 66. By rotating the cam 66, a gradually increasing radius of the cam edge 68 pushes the blade holder 18 and blade 20 downward through the material 100 until a large radius of the cam 66 contacts the blade holder 18 and the blade 20 contacts the blade stop 56 thereby severing the material 100. The resulting cut is optimally free of splinters and a resulting cut end of the material is otherwise clean and straight.
While in the foregoing specification this invention has been described in relation to certain preferred embodiments thereof, and many details have been set forth for purpose of illustration, it will be apparent to those skilled in the art that the material cutter is susceptible to additional embodiments and that certain of the details described herein can be varied considerably without departing from the basic principles of the invention.