GB2551377A

GB2551377A - A cutting device

Info

Publication number: GB2551377A
Application number: GB1610506.6A
Authority: GB
Inventors: Lawrence Ainsworth Gregory
Original assignee: Individual
Current assignee: Individual
Priority date: 2016-06-16
Filing date: 2016-06-16
Publication date: 2017-12-20
Also published as: GB201610506D0

Abstract

A cutting device comprises a body 1, at least one anchor and at least one blade 4, wherein the anchor is arranged to limit movement of the body when the device is in use, and the blade is arranged to displace with reference to the body and the anchor. The anchor may comprise a spike, a cutting implement or one or more blades arranged to pierce wood, which enter the wood in a first direction. In a second direction orthogonal to the first the blade is linearly displaceable. The blade is displaceable along the axis of a guide 3. This guide may comprise two guide members to prevent rotation of the blade with respect to the anchor and body. The blade is supported by a blade housing 2, which is displaceable with respect to the anchor and the body. The body and the blade housing are impact resistant. There are spacers 8 on the bottom of the body in order to vary the depth that the anchor penetrates the wood. There may be a plurality of differently dimensioned blades and anchors. It may also include a protective cover.

Description

A CUTTING DEVICE

Field of the Invention

The present invention relates to a cutting device, in particular for cutting rabbets (rebates); more particularly but not exclusively a cutting device for aiding in cutting rabbets for hinges in doors.

Background

Increasing numbers of people in many societies are becoming interested in home improvement.

However, many people also face a reduction in free time and in disposable income. Consequently, many users find themselves undertaking difficult DIY home improvement or minor building work.

The installation of doors can be particularly difficult carpentry for an inexperienced user. For example, hanging a door correctly and ensuring a door frame is correctly utilised may be difficult without prior experience. Additionally, the cutting of rabbets (also known as rebates) in door frames for the flush-mounting of hinges can be problematic and time-consuming for even the most experienced user.

Prior Art

Accordingly a number of patent applications have been filed in an attempt to resolve the problem or similar, including the following:

United States patent application US 2 440 208 (PARCELL) discloses a hinge setting device comprising a head, a wood severing knife of U-shaped configuration extending beyond a surface of said head, that portion of the knife at the bight of the U being disposed to separate grain of the wood longitudinally and extending beyond said surface a distance greater than the portions of the knife at the adjacent sides of the U, a second head having guide means engaging the first head for relative movement of the two along a plane substantially parallel to the plane of the extremities of said U-shaped knife means, and a second knife carried by said second head for cutting to a predetermined depth the wood within the area incised by said first knife means.

United States patent US 6 267 162 (WILSKE) discloses a mortising tool designed to remove a specific quantity of material from a wooden object, such as a door or door jamb, to allow flush mounting of door hinge plates. The tool is comprised of a mortise forming member, a cutting device attached to the lower surface of the mortise forming member, and a longitudinal slot formed through the mortise forming member.

The cutting edge of the cutting device and the slot are in alignment. Upon placing the cutting device of the mortising tool to one side of the surface of an object from which a mortise is to be formed, material removal is effected by striking the rear portion of the mortising tool and directing it across the object.

Material is removed by the cutting device as the mortising tool is directed across the object, and the slot facilitates waste material removal. The mortising tool is also provided with a shoulder which extends from the lower surface of the mortise forming member for controlling the distance the mortising tool travels when forming a mortise.

International patent application WO 9 323 220 (DEAN) discloses a tool for forming a rebate for a hinge in a wooden workpiece has a body on which is mounted a carrier for a blade having a sharp lower edge, and having (in plan) the shape of three sides of a rectangle. The blades extend through a rectangular opening in the body, so that a rectangular cut may be made in a workpiece when the body is located thereagainst. A second blade is slidably mounted on the body for movement generally at right angles to the movement of carrier, the vertical position of blade being adjustable. The blade may remove material from the workpiece delineated by the blade, so facilitating the production of a rebate for a hinge.

Summary of the Invention

According to the present invention there is provided a cutting device for cutting a rabbet (rebate) in a resilient material which device comprises: a body, at least one anchor and at least one blade, wherein the at least one anchor is arranged to limit movement of the body when the device is in use, and the at least one blade is arranged to displace with respect to the body and the anchor.

In some embodiments the anchor may comprise one or more spikes, blades and/or cutting implements. The spikes, blades, or cutting implements may be arranged to pierce or enter the wood in which the rabbets are being cut.

The anchor or anchors may be arranged to enter the wood in a first direction. The anchor or anchors may therefore act to prevent or limit displacement of the cutting device in directions substantially orthogonal to the first direction, such as for example in a second direction perpendicular to the first direction.

The displaceable blade may be arranged to cut in this second direction. Therefore, anchor will act to prevent the movement of the displaceable blade from displacing or dislodging the device or the anchor from the object in which a rabbet is being cut.

In preferred embodiments, the anchor comprises one or more blades. The blades may extend from the body. In preferred embodiments the cutting edges of the anchor blades define a continuous boundary.

Preferably, the blade is displaceable to and from a closed configuration where the cutting edge(s) of the displaceable blade(s) are in contact with the cutting edge(s) of the blade(s) of the anchor. The displaceable blade may have a cutting edge which matches the continuous cutting edge of the anchor blades.

In preferred embodiments, the points of contact between the displaceable blade cutting edges and the anchor blade cutting edges in the closed configuration define a substantially continuous boundary. In particularly preferred embodiments, in the closed configuration all points on the cutting edge of the displaceable blade are in contact with points on the cutting edge of the blades of the anchor.

In use the anchor blades may be inserted into an object from which a rabbet is to be cut adjacent the edge of the object such that the exterior faces of the object and the cuts made by the blades of the anchor enclose a volume of the object on all but one side. The displaceable blade may then be displaced to the closed configuration where the cutting edges of the displaceable blade and the anchor blades are in continuous contact and the volume is entirely enclosed by the exterior faces of the object and the cuts made by the anchor and the displaceable blade, such that volume is cut from the object to form a rabbet.

In some embodiments the anchor comprises three rectangular blades with cutting edges which together define a continuous boundary in a single plane. Two of the blades may be substantially parallel to each other and may be substantially perpendicular to the third blade so as to define a U-shaped or square bracket shaped anchor with a U-shaped or square bracket shaped cutting edge. The displaceable blade may be a planar blade perpendicular to the anchor blades in the plane of the cutting edge of the anchor. The displaceable blade may also have a U-shaped or square bracket shaped cutting edge which matches the shape of the anchor blade cutting edges.

The anchor blades and/or the displaceable blades may be substantially flat cuboid bodies with bevelled cutting edges.

The anchor and/or the anchor blades may be removable and replaceable from the device and/or the body. A plurality of differently dimensioned anchors and/or anchor blades may be provided which may be swapped between in order to cut rabbets of different sizes and/or dimensions. In some embodiments a plurality of slots may be provided on the body so as to allow a variety of differently dimensioned anchors to be installed in the device, thereby allowing differently dimensioned rabbets to be cut.

Preferably the displaceable blade substantially planar and is linearly displaceable within the plane of the blade. The displaceable blade may be slideably displaceable. The displaceable blade may be substantially perpendicular to the blades of the anchor, and/or may be linearly displaceable in a direction substantially perpendicular to the blades of the anchor.

In some embodiments when the displaceable blade is displaceable to and from a closed configuration where a wall extending perpendicular to the displaceable blade from the cutting edge of the displaceable blade is defined by blades which comprise the anchor.

In some embodiments the displaceable blade is displaceable between a closed configuration, where the displaceable blade and the blades of the anchor define four of the six faces of a cuboid, with the two undefined faces having a mutual edge; and at least one open configuration, where the displaceable blade is not in contact with the blades of the anchor, and the blades of the anchor define two opposing faces of a cuboid and a single additional face of the cuboid.

In some embodiments the device comprises a plurality of different displaceable blades and anchor blades which may be swapped between so as to cut rabbets of different dimensions. The device may comprise a plurality of different displaceable blades and matching associated anchor blades. A length of the blade may define a first dimension of a rabbet cut by the device, for example the length of a cutting edge of the blade may define the first dimension of a rabbet.

In some embodiments the first dimension of rabbet cut by the device may be adjusted by varying the length of the blade. For example, by replacing, reorienting or adjusting the blade.

The travel distance of the blade may define a second dimension of a rabbet cut by the device. The travel distance may be the travel distance in the second direction which is perpendicular to the first direction in which the anchor or anchors enter the wood.

In some embodiments the second dimension of rabbets cut by the device may be adjusted by adjusting the travel distance of the blade.

In alternative embodiments, the second dimension of rabbets cut by the device is determined by the dimensions of the displaceable blade. For example, in some embodiments the displaceable blade has a forward cutting edge and two side cutting edges which may be at right angles to the forward cutting edge.

In some embodiments a third dimension and/or the second dimension are defined by the dimensions of anchor blades which make cuts when they are inserted into the body from which the rabbet is to be cut.

This may enable the device to provide rabbets of pre-defined dimensions, thereby enabling a user to quickly and reputably cut rabbets of desired dimensions.

In some embodiments the device may only cut rabbets with a single predetermined size and dimensions.

Alternatively, the device may be adapted to cut rabbets with different sizes and dimensions.

In some embodiments a user may cut rabbets of different dimensions by adjusting the manner in which they use the device, for example, a user may manually displace the blade different distances in order to cut rabbets of different dimensions.

Alternatively, or additionally, the device may be adjustable so as to adjust the dimensions of the rabbets cut by the device. For example, the blade may be reoriented, adjusted or replaced so as to present a cutting edge with a different length and to cut rabbets of different dimensions.

The means by which the blade is displaced from the body may be adjusted so as vary the distance that the blade travels and the depth of the wood to which it penetrates. The means may be adjusted so as to vary the maximum travel distance of the blade.

In some embodiments the dimensions of the rabbets cut by the device may be adjusted by adjusting the position of the blade. The blade may be displaceable in multiple directions with reference to the body. For example, the blade may be displaceable in a primary direction into the surface of the wood so as to define the depth of the rabbet (this may be a direction perpendicular to the direction in which the anchor or anchors enter the wood) and also in a secondary direction perpendicular to the primary direction so as to increase the length of the rabbet.

The blade may be incorporated in a blade housing. The blade housing may be displaceable with respect to the body and the anchor, and the blade may be rigidly connected to the blade housing such that the blade and the blade housing are displaced together with respect to the anchor and the body. The blade housing may provide a robust weighted blade holder. In this way the housing may be envisaged to improve ease of cutting. A user may be able to manually displace the blade by displacing the blade housing without touching the displaceable blade. Handholds or gripping portions may be provided on the blade housing.

The housing may comprise an impact resistant housing. This may allow a user to use an impact tool such as a hammer in order to drive the blade into an object.

In some embodiments the device may comprise at least one guide. The guide may define an axis along which the displaceable blade and/or the blade housing is displaceable. The guide may maintain the displaceable blade at some fixed depth, height and/o orientation. A guide may advantageously improve the accuracy of a cut be ensuring the displaceable blade is correctly aligned with the object and or the anchor.

In some embodiments the guide may comprise an elongate pole along which the components of the device slide relative to each other. In preferred embodiments the guide comprises at least two elongate poles so as to ensure the displaceable blade slides in a fixed orientation. In a particularly preferred embodiment the guide comprises a pair of elongate poles rigidly affixed to the blade housing, and a pair of apertures through the body of the device, through which the poles slide.

In some embodiments the device is made up of two parts, a head cutter or anchor part, which comprises the body and the anchor, and a sliding blade carrier or blade part, which comprises a blade housing and the blade. These two parts may be connected by a guide and are displaceable with respect to each other.

In some embodiments the device and particularly the blade part may be impact resistant to allow the user to hammer the part into the door frame. The blade carrier or blade part may be impact resistant to enable the displaceable blade to be hammered in, and the head cutter or anchor part may be impact resistant to enable the anchor to be hammered in.

In some embodiments the axis along which the displaceable blade is displaceable may be displaceable with respect to the body and the anchor so as to enable differently dimensioned rabbets to be cut.

In some embodiments spacer may be used to vary the axis along which the displaceable blade is displaceable with respect to the body. In some embodiments spacer may be used to space the displaceable blade away from the blade housing and/or a guide.

Alternatively, spacer may be provided which may be positioned on or affixed to the lower surface of the body, adjacent the anchor, thereby adjusting the distance between the lower surface of the body and the cutting edges of the anchor and reducing the depth to which the anchor penetrates a surface.

For example, spacers may comprise an outer trim or U shaped plate between the blade and the blade carrier that attaches thereto and is adjustable in height for the user to specify the depth to which the blades cut into the wood when struck with a hammer.

In some embodiments spacer may be used to increase the depth to which the anchor penetrates an object and to vary the depth of rabbet cut by the device.

In some embodiments, he parts comprising the blade and anchor(s) may be arranged to mutually move through use of a non-rotational means or member. The member may extend and retract by approximately 3 inches at most.

In some embodiments the device may comprise a means of collecting or channelling material cut from an object. This may allow the collection or ejection of wood waste after the device is used to cut a rabbet.

In some embodiments the device comprises a removable cover. The removable cover may cover the blade and/or the anchor when it is attached to the device. In some embodiments the cover may only be attached to the device when the displaceable blade and/or the blade housing is displaced to a closed configuration.

Brief Description of Figures

Figure 1 shows an isometric view of an embodiment of the device in a closed storage and transport configuration;

Figure 2 shows an isometric view of the device shown in Figure 1 in an open configuration;

Figure 3 shows a reserve isometric view of the device as shown in Figure 2;

Figures 4 show isometric exploded views of the blade part of the device shown in Figure 1;

Figure 5 shows a reverse isometric view of the device as shown in Figure 1;

Figure 6 shows an isometric view of the device shown in Figure 1 with a smaller blade and anchor;

Figures 7 show a bottom view, front view, side view, top view, side view and rear view, respectively, of the device as shown in Figure 1;

Figures 8 show isometric exploded views of the anchor part of the device shown in Figure 1; and

Figure 9 shows a sketch isometric view of an embodiment of a cover for the embodiment of the device shown in Figure 1.

Detailed Description of Figures

With reference to the figures generally there is shown an embodiment of the invention. There is shown a device for cutting a plurality of differently dimensioned rebates in wood. The device comprises a body 2, a blade housing 1 slideably connected to the body by a guide 3, and two blades 4, 44 and associated anchors 10, 11 allowing for rabbets of different lengths to be cut by the device. The device also comprises a plurality of spacers 8 which allow rabbets of different depths to be cut. The widths of the rabbets cut by the device may be varied by varying the distance from the edge in which the rabbet is being cut that the anchor 10, 11 is inserted. The device additionally comprises a cover 21 for when not in use.

In figures 2, 4a, 4b and 5 the blade housing is incorrectly labelled with reference numeral 2 instead of 1. In figures 2 and 5 the body is incorrectly labelled with reference numeral 1 instead of 2.

The device is a bipartite device. The device comprises two parts, a head cutter anchor part, which comprises the body 2 and the anchor 10, 11, and a sliding removal core or blade part, which comprises the blade housing 1 and the blade 4, 44.

The parts are arranged to move linearly towards and away each other, along guides 3, said guides comprising elongate aluminium poles which extend from the blade housing 1 and slot through sleeves 33 in the body 2 of the anchor part.

The body 2 and the blade housing 1 are both substantially cuboid with faces which come into contact when the device is in a closed configuration (shown in Figs, 1, 5. 6 and 7). The body 2 and the blade housing 1 have a shared side indent 5, into which a user may insert their fingers in order to more easily manipulate the device, for example when withdrawing the blade 4, 44 after a cut has been made. The body and the housing are cast for robustness, so as to withstand impacts, this enables them to be hammered in order to drive the anchor 10, 11 and the blade 4, 44 into an object to be cut. In particular, the upper surface of the body 2 (opposite the anchor 10, 11) and the rear face of the blade housing 1 (opposite the guides 3), are adapted to be resistant to impacts.

The blade 4, 44 is set to a constant height in use (with reference to a horizontal plane in which the blade 4, 44 is located). The device is supplied with a plurality with spacer plates 8 which may be affixed to the bottom of the body, thereby adjusting the height of the blade 4, 44 and anchor 10, 11 cutting edges with respect to the body. This adjusts the depth to which the anchor penetrates the object from which the rabbet is being cut and therefore may be used to vary the depth of rabbets cut by the device. The spacer plates are positioned along three edges of the underside of the body 2

The blades 4, 44 are substantially flat and rectangular. The blades comprise bevelled cutting edges along a front edge and along forward portions of the side edge of the blade. A blade with a 3” forward cutting edge is provided 44 and a blade with a 4” forward cutting edge 4. This allows rabbets for 3” and 4” hinges to be cut using the device. A pair of apertures 14 are provided through the blades, through which bolts 17 pass in order to secure the blades 4, 44 to the under surface of the blade housing.

The cover 21 shown in Figure 9 fits over the blade 4, 44 and the anchor 10, 11 when the device is not in use, for transport or storage. The cover 21 may be attached when the device is in a closed configuration, with the blade housing 1 in contact with the body 2. The cover 21 includes storage space for additional blades and anchor blades. This cover 21 is pushed over the bottom of the device to protect the blades.

The device in the pictured embodiments is formed of two main cast iron or aluminium body parts 1, 2. The cover 21 is silicone.

The device can be set up to cut recesses for either 3 inch or 4 inch hinges, wherein Figure 1 shows a larger blade 4 in use, and Figure 3 a smaller blade 44.

The blades are drop forged for strength and then sharpened to 30°. A rabbet 12 is formed in the bottom of the blade housing 1. The rabbet is the width of the wider 4” blade, and it is into this rabbet that the blades are affixed in use, such that the upper surface of the blade 4, 44 is coplanar with the under surface of the blade housing 1. Bolt holes 15 are formed in the under surface of the blade housing 1 into which bolts 17 which pass through the holes 14 in the blades 4, 44 are screwed. In other embodiments oval slots may be used to fix the blade in place so that the forces acting on them are linear and do not translate through the bolts. The blades are screwed to the blade housing, using hex head bolts 6.

The anchors comprise blades which extend vertically from the under surface of the body 2. Slots are formed in the under surface of the body 2 into which the anchor blades 10, 11 are inserted and within which they are held in place by bolts. Two smaller anchor blades 11 are positioned on opposite sides of the body 2, extending parallel to the guides 3 and to the side edges of the blade 4, 44, these blades have lengths equal to the side cutting edges of the displaceable blade 4, 44. A single larger anchor blade 10 is positioned at right angles to the smaller anchor blades 10 and parallel to the forward cutting edge of the displaceable blade 4, 44.

This blade has equal length to the length of the forward cutting edge of the displaceable blade being used 4, 44 (either 3” or 4”) and extends between the ends of the smaller anchor blades 11. Two pairs of slits (14 and 15 in Fig. 8a) are provided for the smaller anchor blades 11, a first pair 3” apart and a second pair 4” apart, a perpendicular slot (16 in Fig. 8a) is large enough to accept either the 3” or the 4” anchor blade. The blades are rectangular, drop-forged and sharpened to 30 degrees.

The anchor blades are held in place by hex head bolts 13 which pass through the anchor blades and the edges of the slits. In some configurations the shorter blades 11 may be clamped against the side wall of the shim which defines the inside of the interior slits. When the displaceable blade 3, 44 and the blade housing are slid into the closed configuration, the cutting edges of the displaceable blade 4, 44 are in continuous contact with the cutting edges of the anchor blades 10, 11, such that the anchor blades extend vertically from edges of and perpendicular to the displaceable blade.

The walls of the slits formed in the bottom of the body are perforated by perforations 7 for access to the screws or bolts as necessary.

The depth of the cut (the depth with which the anchor penetrates the object being cut) can also be set from 3mm to 4mm. A plurality of 1mm magnetic adjustment plates can be used to increase the depth. The device is shown set up in Figure 1 for a 3 inch cut with a depth of 4mm.

In place of the hex head bolts, there may be used: M4 20mm Countersunk Screws IVI4 30mm Countersunk Screws (for 13) M4 16mm Countersunk Screws (for 17) M4 20mm Grub Screws

The guiding members 3 have circular cross-sections as a cylindrical hole is the simplest to machine in the body 2. As there are two guiding members, the blade 4, 44 and the blade housing 1 are not able to rotate with respect to the body 2 and the anchor 10, 11.

The cover 21 comprises the following:

Slots 22 to aid the removal of additional blades.

Internal ribbing 25 increases robustness and provides surfaces for the tool to rest on. Recess 24 for additional blade storage, shown with a longer anchor.

Studs 23 for spacing of blades.

Once the door frame has been cut a small section exists to the edges of the rebate. This prevents the blade from interfering with chamfered sections of the vertical anchors. This will also allow the anchors to grip into the wood whilst the blade is being hammered in.

The invention has been described by way of examples only and it will be appreciated that variation may be made to the above-mentioned embodiments without departing from the scope of invention as defined by the claims, in particular but not solely combination of features of described embodiments.

Claims

1. A cutting device for cutting rebates in wood, which device comprises a body, at least one anchor and at least one blade, wherein the anchor(s) is/are arranged to limit movement of the body when the device is in use, and the blade(s) is/are arranged to displace with reference to the body and the anchor.

2. A device according to claim 1 wherein the anchor comprises a spike or cutting implement, arranged to pierce or enter wood.

3. A device according to claim 1 or 2 wherein the anchor or anchors is/are arranged to enter the wood in a first direction.

4. A device according to claim 3 wherein the displaceable blade is linearly displaceable in a second direction orthogonal to the first direction.

5. A device according to any preceding claim wherein the anchor comprises one or more blades.

6. A device according to claim 5 wherein the displaceable blade is displaceable to and from a configuration where the cutting edge(s) of the displaceable blade are in contact with the cutting edge(s) of the anchor blades.

7. A device according to claim 5 or 6 wherein the displaceable blade is displaceable to and from a configuration where the points of contact between the cutting edges of the displaceable blade and the cutting edges of the anchor blades define a continuous boundary.

8. A device according to any of claim 5, 6 or 7 wherein the displaceable blade is displaceable between a closed configuration, where the displaceable blade and the blades of the anchor define four of the six faces of a cuboid, with the two undefined faces having a mutual edge; and at least one open configuration, where the displaceable blade is not in contact with the blades of the anchor, and the blades of the anchor define two opposing faces of a cuboid and a single additional face of the cuboid.

9. A device according to any preceding claim comprising which along which the displaceable blade is displaceable.

10. A device according to claim 9 wherein the guide defines an axis along which the displaceable blade is displaceable.

11. A device according to claim 9 or claim 10 comprising two guide members to prevent rotation of the displaceable blade with respect to the body and the anchor.

12. A device according to any proceeding claim comprising a blade housing which supports the blade and is displaceable with respect to the anchor and the body.

13. A device according to claim 12 wherein the blade housing is impact resistant.

14. A device according to any preceding claim wherein the body is impact resistant.

15. A device according to any preceding claim wherein the blades are wholly displaceable.

16. A device according to any preceding claim comprising a plurality of differently dimensioned blades and anchors.

17. A device according to any preceding claims wherein spacers may be attached to the body in order to vary the depth to which the anchor penetrates a surface.

18. A device substantially as described herein with reference to the figures.