WO2022152359A1

WO2022152359A1 - Portable automated drywall board cutter

Info

Publication number: WO2022152359A1
Application number: PCT/DK2022/050006
Authority: WO
Inventors: Peter Murmann HARTVIGSEN; Kristian DALGAARD
Original assignee: Kobots Aps
Priority date: 2021-01-18
Filing date: 2022-01-18
Publication date: 2022-07-21
Also published as: DK202170024A1

Abstract

The invention relates to a portable automated drywall board cutter (1) comprising a housing (2) having at least one board drive (3) configured for moving a board (4) along a first axis through a board inlet opening (5) and out of a board outlet opening (6) of the housing (2) while cutting, an upper cutting device (7) and a lower cutting device (8) is positioned between the board openings (5, 6) and is configured for cutting the board (4), the cutting devices (7, 8) are movable along a second axis by an upper cut drive (9) and a lower cut drive (10) respectively. The control of the cutting drives (9, 10) and thereby the movement of the cutting devices (7, 8) along the second axis and the control of the at least one board drive (3) and thereby the movement of the board (4) along the first axis is automatically coordinated by the controller (11) to facilitate coordinated movement of the board (4) and the cutting devices (7, 8) according to a cutting pattern.

Description

PORTABLE AUTOMATED DRYWALL BOARD CUTTER

Field of the invention

[0001] The invention relates to a portable automated dry wall board cutter, a method of controlling such board cutter and a system comprising such board cutter.

Background of the invention

[0002] In the art, a whole range of manual gypsum board cutters are known. As an example, CN210148445 could be mentioned which discloses a portable gypsum board cutter cutting the board on both sides by two knives fixed in a mounting seat. The gypsum board is cut by hand dragging the knives by pulling a handle.

[0003] Another example is FR2990374 disclosing a cutter having an upper and a lower part between which the board to be cut can pass. At the correct measure, the length of the board is manually cut.

[0004] A problem with prior art drywall cutters is the manual handling of board and cutter leading physical degradation of health of the person performing the cutting.

Summary of the invention

[0005] The present invention solves the problem of the prior art by introducing a drywall board into an automatic drywall board cutter which is controlling both the moving of the board through the board cutter and the cutting tool of the cutting device.

[0006] The invention relates to a portable automated drywall board cutter comprising a housing having at least one board drive configured for moving a board along a first axis through a board inlet opening and out of a board outlet opening of the housing while cutting, an upper cutting device and a lower cutting device is positioned between the board openings and is configured for cutting the board, the cutting devices are movable along a second axis by an upper cut drive and a lower cut drive respectively. The control of the cutting drives and thereby the movement of the cutting devices along the second axis and the control of the at least one board drive and thereby the movement of the board along the first axis is automatically coordinated by the controller so as to facilitate coordinated movement of the board and the cutting devices according to a cutting pattern.

[0007] Cutting on both sides of the board is advantageous in that it has the effect, that the work person / user only needs to break the board where the board cutter has cut i.e. no subsequent manual cutting is required.

[0008] Automatic coordinated cutting performed by a portable automated drywall board cutter is advantageous in that precision and accuracy of the cutting is increased while at the same time ergonomic positions of a work person cutting a drywall board without a portable automated drywall board cutter of the present invention is eliminated. Further, total time of cutting and thereby also covering a surface with drywall board cuttings is reduced compared to similar work performed manually. Further, since the automated drywall board cutter is portable i.e. movable, such as liftable transportable, by preferably one or two work persons, it is possible to bring and use the board cutter even in small spaces, such as a room, of a construction site. In one implementation, the drywall board cutter can be equipped with wheels in one end enabling one person to lift the opposing end and thereby move / lift the drywall board cutter assisted by the wheels. It should be noted, that in an embodiment, the drywall board cutter may be equipped with wheels and an attachment for mounting it to a tow bar of a vehicle.

[0009] Note that the coordinated control of cutting device and board drive may include moving of the cutting devices while not moving the board drive an vice versa. In this way e.g. a cut across the board from one side to the other (perpendicular to both sides) can be made (board drive is not moved, while cutting devices are) and a cut along the length of the board from one end to the other end (perpendicular to both ends) can be made (board drive is moved, while cutting devices are not).

[0010] A surface should be understood as something that is to be covered by drywall boards include walls, ceilings, coverings of e.g. ventilation or radiators, etc. i.e. everything that can be covered by drywall board. A cutting should be understood as a piece of a drywall board that is covering part of a surface. Hence, a cutting could be a complete drywall board or a part hereof. Typically, the surface of a wall is covered by both complete drywall boards and parts of drywall boards that are cut according to a predetermined cutting patter. Accordingly, from one drywall board only part of a surface can typically be covered (depending on size, naturally). The predetermined cutting pattern should therefore be understood as a set of measures defining where a drywall board should be cut to fit as part of a drywall board cover such as e.g. a cover / building of a wall.

[0011] The establishing of a cutting pattern and thereby how a board is to be cut can be done manually, semi-automatic or fully automatic. A manually established cutting pattern is in an embodiment established by a work person taking measure on the longitudinal direction (first axis or X axis) and transversal direction (second axis or Y axis) and provide these measures to the controller of the cutter preferably via a portable user device. A semi-automatic establishing of a cutting pattern is established by a work person using e.g. the portable user device or an intelligent measuring tape to measure the longitudinal and transversal measures of a desired cutting. A fully automatic establishing of a cutting pattern can be established by a device such as a 3D scanner connected to the portable user device or by the portable user device scanning, based on blueprints of the surface or other ways of picturing the surface to cover. Based on such automatic generated picturing of the surface to be covered, the controller may automatically generate the measured required to establish cutting patterns of cuttings that are needed to cover the surface.

[0012] The cutting pattern may be predetermined in the sense that the measures defining it is provided prior to starting the cutting operation this is especially true when the cutting pattern is automatically generated. Hence, the cutting pattern separates a part of the board which is to be used by the work person from a part of the board that is not going to be used by the work person. With this said, the latter part may also be used by the work person with or without subsequent cutting. [0013] Finally, note that predetermined generic cutting patters may be accessible via the portable user device. Hence, only the desired measures of e.g. a generic square cut may need to be provided by the user to establish a desired cutting pattern of a board.

[0014] In an exemplary embodiment of the invention, the first axis is in a horizontal plane, in a vertical plane or in a plane therebetween.

[0015] In an exemplary embodiment of the invention, the cutting pattern is cut in both sides of the dry wall board.

[0016] Controlling both the upper and lower cutting devices to cut in the board is advantageous in that it has the effect, that the cutting is easier to separate from the remaining dry wall board and the cut is made equally sharp on both sides of the board. A board side is defined as upper or lower side with respect to the boards position in a horizontal plane when moved into the board cutter along the first axis. Especially, this is advantageous when e.g. a hole has to be made in a board to ease the removal of the part of the board that needs to be removed to establish the hole.

[0017] In an exemplary embodiment of the invention, the drywall board cutter is configured to move the dry wall board both into and out of the inlet opening during the cutting operation.

[0018] Moving the board both forth and back along the first axis and threby in and out of both the inlet and outlet simultaneously while cutting is advantageous in that more sophisticated cuttings can be made i.e. not only a transverse or longitudinal cut.

[0019] In an exemplary embodiment of the invention, a portable user device is configured for receiving measures of the cutting pattern via predetermined cutting offs.

[0020] Using cutting offs for receiving measures provided by a user is advantageous in that it has the effect, that communication between work person and board cutter is easier, faster and less prone to errors.

[0021] In an exemplary embodiment of the invention, the upper cut drive and a lower cut drive are independently controllable. [0022] Independently controlling of the cut drives is advantageous in that it allows cutting only on one side of the board. Cutting only in one side of the board may facilitated removal of material of the board and hence, if e.g. the board is a gypsum board, a curved bending of the gypsum board is possible. Accordingly, it is possible to cut slices of gypsum away from one side while not cutting in the other side and the removal om slices of material makes it possible to form a curved bending of the gypsum board with the non-cut side outwards.

[0023] Further, non-synchronous cutting of the board on both sides is possible. Non- synchronous cutting should be understood as the board is cut according to the same cutting pattern on both sides but where one of the cutting devices is lagging the other. Further, non-synchronous cutting should be understood as the two cutting devices are cutting according to the same cutting pattern on both sides, but displaced in the X plan so that when breading the board, the edge of the board is inclining.

[0024] In an exemplary embodiment of the invention, the upper cut drive and the lower cut drive facilitates moving the upper and lower cutting devices along a third axis.

[0025] The third axis is also referred to as the Z axis and is perpendicular to the X / Y plane i.e. the cutting devices can be moved upwards, away from the board, and downwards, towards the board. This is advantageous in that if e.g. a hole is to be cut in the “middle” of a board, this can be done without making a cut from an edge / side of the board and into the location (the “middle”) of the hole. Thereby, the board is not unnecessarily weakened in case a hole is to be made in a board.

[0026] In an exemplary embodiment of the invention, each of the upper and lower cut drives comprises fasteners configured for fastening the cutting devices to a drive part and a motor configured to move the drive part along the second axis and thereby the cutting devices along the along the second axis.

[0027] The fasteners may be part of what is also referred to as a connector block. [0028] In an exemplary embodiment of the invention, at least one of the fasteners is configured to lock the associated cutting device in an angle around the third axis.

[0029] This is advantageous in that it has the effect, that independent of cutting pattern, the cutting device follows the path of the cut drive.

[0030] In an exemplary embodiment of the invention, the cutting devices (7, 8) are rotatably mounted so as to facilitate rotation of at least 180° [deg], preferably 360° [deg] around the Z axis.

[0031] This is advantageous in that it has the effect, that the number of different cutting patterns that can be cut in one work procedure is increased. Hence, e.g. a circle do not require moving the board without cutting in the board which would be needed if the freedom of the cutting devices around the Z axis were e.g. 180 degrees.

[0032] In an exemplary embodiment of the invention, force is applied to the upper and lower cutting devices. This is advantageous in that it has the effect, that, the board is not pushed out of position by one of the cutting devices.

[0033] In an exemplary embodiment of the invention, the same force is applied to the board from the upper and lower cutting devices.

[0034] Applying the same or substantially the force from both the upper and lower cutting device is advantages in that no support is needed for the board at the point opposite the cutting device cutting the board. This would be needed if force only is applied from one cutting device on one side of the board. In an embodiment of the invention, the orientation of the board being cut while entering and exiting the dry wall board cutter is so that the upper side (being cut by the upper cutting device) may be referred to as front of the board while the lower side (being cut by the lower cutting device) may be referred to as the back of the board.

[0035] In an exemplary embodiment of the invention, the upper and lower cutting device are selected from the list comprising: knife, drag knife, tangential knife, wheel cutter, milling tool and toothed wheel cutter. [0036] These types of cutting devices are advantageous in that they can be mounted to follow the cutting drive which is controlled by the controller according to the cutting pattern. The drag knife is particularly advantageous if the board to be cut is a gypsum board in which only the cardboard layer is to be cut. The toothed wheel cutter is advantageous if the board to be cut is a gypsum fibre board which needs to be fully cut through.

[0037] In an exemplary embodiment of the invention, the controller is configured to add an offset to the cutting pattern if the cutting pattern includes a curve.

[0038] This is advantageous in that if the cutting device is of a drag knife or a dragged toothed wheel cutter type, then a risk exists that the cutting device does not follow the exact same path as the cutting drive in that the cutting device is “dragged” after he cutting drive. To compensate for this, an offset may be added to the measures provided by the user to the controller, when these measured are converted to a cutting pattern.

[0039] In an exemplary embodiment of the invention, the at least one board drive is configured for moving the board along the first axis by a conveyer element mechanically connected to a motor.

[0040] A board drive connected to and controllable by a motor is referred to as an active board drive. This is advantageous in that it has the effect, that thereby the board is automatically moved into an area of the board cutter where the cutting device(s) is able to cut a cutting pattern in the board. In a horizontal cutter, the active board drive is in contact with the side of the board whereas in a vertical cutter, the active board drive is in contact with the longitudinal end / side of the board (defining the width of the board) i.e. the board is moved standing on the side.

[0041] In an exemplary embodiment of the invention, the at least one board drive is a lower board drive and wherein the drywall board cutter further comprises at least one upper board drive.

[0042] Having an upper board drive controllable by the controller is advantageous in that even a part of a board to be cut that is smaller than a complete size board can be cut. Depending on size of the part, this might not be possible in that weight of the part of the board may not be enough to establish sufficient contact between the part of the board and the lower board drive for the lower board drive to move the part of the board along the first axis. This problem is solved by controlling the movement of the board by both an upper and a lower board drive between which the board is introduced and in contact. The contact between the board / part of the board and the upper board drive is balanced between friction and force to enable the lower board drive to move the board.

[0043] In an exemplary embodiment of the invention, the board drives comprise a conveyer element.

[0044] The conveyer element may be any kind of roller or smooth planer surface allowing a force against the board with reduced friction allowing the lower board drive to move the board.

[0045] In an exemplary embodiment of the invention, the conveyer element is mechanically connected to a board drive motor.

[0046] Being able to control both the upper and the lower board drives is advantageous in that it has the effect, that thereby the movement of the board long the first axis is controllable. Hence, if measuring devices / sensors informs the controller, that there is a deviation between the movement of the board and the firs axis, independent control of one of the board drives can be used to align the movement of the board with the first axis.

[0047] In an exemplary embodiment of the invention, the direction of rotation of the motor(s) is controllable by the controller according to the cutting pattern.

[0048] This is advantageous in that it has the effect, that the board can be moved both forth and back relative to the housing by the board drive and thereby increasing cutting flexibility i.e. allow a greater number of different cutting patterns.

[0049] In an exemplary embodiment of the invention, the drywall board cutter comprises a least two active board drives. [0050] Having two or e.g. four active board drives is advantageous in that it has the effect, that movement of the board along the first axis can be facilitated from inside the housing on both sides of the cutting device(s). Hence, if desired, a board can automatically be moved through the housing i.e. into the housing from a first side to obtain contact with the cutting devices and out of the housing from a second side of the housing.

[0051] In an exemplary embodiment of the invention, the controller facilitates coordinated control of the upper and lower cut drives and of the board drive so that the board is moved along the first axis simultaneously with movement of the upper and lower cutting devices along the second axis and third axis.

[0052] This is advantageous in that it has the effect, that if the cutting device is a knife, a cutting pattern does not have to start at a side / edge of a board. Hence, the cutting time of at least some cutting patterns would be reduced. An example of such cutting pattern is if the cutting pattern includes two slant cuts that meets in the “middle” of a board and is continuing towards opposite sides of the board. In such example, the board does not have to be moved to the point where the first slant cut meets the first side, back to the meeting point of the two slant cuts and again forward to the location where the second slant cut meets the second side of the board.

[0053] Further independent of type of cutting device, the load on the cut drive and cutting device compared to the situation where the cutting device is only moved downwards towards the board along the third axis.

[0054] In an exemplary embodiment of the invention, the controller and the portable user device is configured to communicate wirelessly.

[0055] Wireless communication via Bluetooth or WiFi as examples are advantageous in relation to this invention, in that the user is able to provide measures of a cutting pattern to the board cutter even when the user is not physically next to the board cutter. [0056] In an exemplary embodiment of the invention, wherein the drywall board cutter is configured for cutting a gypsum board comprising a gypsum layer sandwiched between two cardboard layers and wherein at least one of the cutting devices only cuts through one of the cardboard layers.

[0057] Cutting through only the cardboard is advantageous in that it has the effect, that less force needs to be applied to the cutting device and that the cutting device does not get blunt because it does not cut in the gypsum. Thereby the lifetime of the cutting device is increased and the time between service of the board cutter 1 is increased.

[0058] Moreover, the invention relates to a method of cutting a dry wall board, comprising the steps of: a) establish a cutting pattern, reflecting at least part of a surface to be covered by one or more drywall board cuttings, on a portable user device, b) provide the cutting pattern to a controller of a drywall board cutter, c) initiate the cutting of the board, d) by the controller: control a board drive and thereby movement of the board through a board inlet opening and a board outlet opening of a housing in a first direction, and control at least one of an upper cut drive mechanically coupled with an upper cutting device and a lower cut drive mechanically connected to a lower cutting device and thereby movement of at least one of the upper and lower cutting devices in a second direction, wherein the control of movements of the board and cutting devices is automatically coordinated to cut the cutting pattern in the board while the board enters the board inlet opening and exits the board outlet opening.

[0059] Establishing the cutting pattern includes at least provide measures to the controller.

[0060] This method is advantageous in that it has the effect, that only manual work related to cutting a board is establishing a desired cutting pattern and load the board cutter with a board. Both of these manual steps may even be automated if the portable user device is able to scan a surface to be covered or communicate with a scanner device and if a feeder for feeding boards to the board cutter is provided. Accordingly, an effect of the board cutter and method of cutting a board according to the present invention is better work positions and reduced physical work required by a work person related to cutting of boards. Thereby physical disabilities, degradation and physical wear over timed of the work person related to handling of boards to be cut is reduced.

[0061] Initiating the cutting of a board may include positioning of a board in the inlet opening and thereby facilitate movement of the board by means of the board drive. Further, initiating may include, via the portable user device, acknowledge of a “ready to cut” signal sent from the controller. Further, initiating may include approving a cutting pattern suggested by the controller or by the portable user device.

[0062] Note that the terms parallel and perpendicular should be understood as substantially parallel and substantially perpendicular. The closes to parallel and perpendicular, the easier the design of the control software will be in that, preferably no compensation for misalignments needs to be implemented.

[0063] In an exemplary embodiment of the invention, the method is implemented in a portable automated drywall board cutter according to any of paragraph’s 5-57.

[0064] In an exemplary embodiment of the invention, the first direction is perpendicular to the width of the inlet opening of the housing.

[0065] In an exemplary embodiment of the invention, the second direction is parallel to the width of the inlet opening.

[0066] In an exemplary embodiment of the invention, the measures of a desired cutting pattern are communicated wirelessly to the controller via the portable user device.

[0067] In an exemplary embodiment of the invention, the cutting is initiated wirelessly by a user via the portable user device.

[0068] Wireless communication and thereby control via a portable user device are advantageous in that it has the effect, that the user is able provide measures to the board cutter while being in visual contact with the surface and not with the board cutter. Thereby, the user does not have to remember measures of a cutting pattern, the user is able to register (by voice or tapping in) measured real-time as these are made. Note, that the communication may also be established via a wired connection.

[0069] It should be mentioned, that cutting patterns may also be communicated wired or wireless to the controller from a device, computer, server or cloud service. This is advantageous in that measures from a digital measuring tape or CAD files from a computer can be communicated to the board cutter.

[0070] In an exemplary embodiment of the invention, at least two cutting patterns are communicated to the controller and wherein the controller is nesting the at least two cutting patterns.

[0071] Nesting is advantageous in that it has the effect, that the exploitation of the boards is increased i.e. the number and sizes of remaining parts of a board is reduced. Hence, this leads to a better utilisation of each individual board.

[0072] In an exemplary embodiment of the invention, at least one of the cutting devices is marking the cuttings.

[0073] In an exemplary embodiment of the invention, the board cutter comprises a marker, and wherein the board cutter is marking cuttings with the marker.

[0074] Marking a cutting is advantageous in that if two or more cuttings are made which are not to be used as the next cuttings in the work process, than the marking helps the user to keep track of the when and where these cuttings are to be used. In an embodiment, the portable user device provides a guide or map of where cuttings are to be used / mounted.

[0075] Markings with cutting devices may be cuts such as lines, numbers, letters, etc. whereas a marker may be a pencil, painter, stamper or the like that can mark the cuttings of a board.

[0076] In an exemplary embodiment of the invention, the establishing of a cutting pattern is made based on predefined cutting off. [0077] A predefined cutting offs may be a sloping cutting off defined by one value of X (of the first axis, typically length) on one side of the board to another value of X on the other side of the board. A straight end cutting off from the same value of X on both sides of the board. A straight length cutting off from the same value of Y (of the second axis typically width of board) at both ends of the board, etc. The use of predefined cutting offs defined by measures of the desired geometry of the part of the board that the work person is going to use, is advantageous in that it has the effect, that it is faster to provide measures to the controller and thereby the establish a cutting pattern and ultimately to cut the board.

[0078] In an exemplary embodiment of the invention, the method further comprises the step of providing board thickness to the controller.

[0079] This is advantageous in that it has the effect, that then the controller is able to automatically adjust the dept of the cut according to board thickness by controlling third axis coordinate of cutting drive or cutting device. Further, it is possible to automatically adjust height of the inlet opening according to the top board of a stack of boards to be cut.

[0080] In an exemplary embodiment of the invention, the method further comprises the step of providing information to the controller that a board has been removed from a stack of boards.

[0081] This is advantageous in that it has the effect that automatic hight adjustment of the inlet opening is facilitated.

[0082] In an exemplary embodiment of the invention, the method furthermore comprises the step of adjusting height of the inlet opening of the portable automated panel cutter.

[0083] This is advantageous in that not necessarily all boards of a stack of boards needs to be cut. Hence, the work person may take one or more boards from the stack without cutting and thereby without knowledge of the controller of the board cutter. Hence, prior to cutting a board, the work person may input a number of boards that is removed since last cutting. Alternatively, the board cutter is equipped with a sensor that informs the controller of the board cutter of the hight of the upper board of the stack of boards which then can automatically adjust the height.

[0084] In an exemplary embodiment of the invention, the height of the inlet opening is adjusted by adjusting length of legs of the portable automated panel cutter.

[0085] Adjusting length of legs of the board cutter is advantageous in that it has the effect, that reducing height of the inlet opening of the board cutter with the thickness of one board enables a user to simply push the next board to be cut into the inlet opening / into contact with the board drive, without lifting the board and thereby reducing board handing and degradation of health of the work person (work person is also sometimes referred to as user).

[0086] Moreover, the invention relates to a drywall board cutter system comprising a portable automated drywall board cutter, a board feeder and a board storage. The drywall board cutter comprising a housing configured for receiving a board through a board inlet opening and exit the board cut through an outlet opening while cutting, between the board openings at least an upper cutting device is positioned, the cutting device is controlled by an upper cut drive, the cut drive includes a motor controllable by a controller. The board feeder is configured to provide the upper board of a stack of drywall boards to be cut to the inlet opening in a first plan, and wherein the board storage is configured to receive boards, that are cut, from the outlet opening in the first plan.

[0087] The first plan may be horizontal, vertical or therebetween i.e. between 0 degrees and 90 degrees both included (measured from horizontal).

[0088] In the embodiment where the first plan is horizontal, the board storage should be in a height that does not provide so much force (from gravity) that it facilitates breaking (or separating) the part of the board that is not cut by the cutting device. In an alternative embodiment, the different in hight between the output and the board storage is enough to break the board where it is cut. [0089] The difference between horizontal plan of board feed / storage at the inlet / outlet, if not the same, is preferably larger at the outlet. If so, the storage can store more than one cut board at the time without being able to adjust height of the board storage.

[0090] In an exemplary embodiment of the invention, the system comprising a drywall board cutter according to any of the paragraph’s 5-57 and controlled according to a method of any of the paragraph’s 58-85.

[0091] In an exemplary embodiment of the invention, the board feeder comprises a stack of drywall boards to be cut, wherein the stack of drywall boards comprises at least two drywall boards.

[0092] Having a stack of boards in front of the inlet opening and in substantially the same height is advantageous in that the work person (or the cutter if equipped with means facilitating this) is able to simply push a new board into the cutter or at least only lift the end of the board for it to be introduced into the cutter. Thereby avoiding health degradable positions of the work person.

[0093] In an exemplary embodiment of the invention, height of legs of the board cutter is adjustable to facilitate continuous introduction of the upper board from the stack of drywall boards into the inlet opening.

[0094] The horizontal introduction of boards into the cutter may be facilitated by adjusting height of legs of the board cutter.

[0095] In an exemplary embodiment of the invention, the board feeder comprises a mechanic spring arrangement automatically ensuring substantially the same height of the upper board from the stack of drywall boards as boards are removed from the stack of drywall boards.

[0096] In an exemplary embodiment of the invention, the board feeder is at least partly implemented as a pallet. [0097] This is advantageous in that it has the effect, that a stack of boards to be cut, does not have to be handled, the cutter can simply cut from the stack of boards as delivered to the construction site.

[0098] In an exemplary embodiment of the invention, the board storage comprises at least one board support.

[0099] The board storage may in an embodiment only support the cut board while it is being cut. When the cut is completed, it may be moved to back to the stack and removed before the next board can be cut. This has the effect, that footprint of the system may be reduced, total weight of the system is reduced and assembly time is reduced.

[0100] In an exemplary embodiment of the invention, the board storage comprises at least one board guide.

[0101] To ensure that no matter the length, the cut board is supported a board guide is mechanically connecting the cutter and the board support. [0102] In an exemplary embodiment of the invention, the board support and / or the board guide comprises conveying elements.

[0103] In an exemplary embodiment of the invention, the height of the board support is adjustable.

The drawings

[0104] For a more complete understanding of this disclosure, reference is now made to the following brief description of figures illustrating the invention in different embodiments, taken in connection with the accompanying drawings and detailed description, wherein like reference numerals represent like parts. To increase simplicity of the figures, the parts are not illustrated in the same detailed level on all figure.

Fig. 1 illustrates a board cutter in a perspective view,

Fig. 2a illustrates the board cutter seen from the back, Fig. 2b illustrates the board cutter seen in a front view,

Fig. 3 illustrates a cross-sectional view of the board cutter at line A of Fig. 1,

Fig. 4 illustrates a surface to be covered by drywall boards,

Fig. 5 illustrates a horizontal board cutter system,

Fig. 6 illustrates a vertical board cutter system, Fig. 7a illustrates a view of the vertical board cutter from the inlet opening side, and

Fig. 7b illustrates a front view i.e. a view into the vertical board cutter when the front cover is removed.

Detailed description

[0105] Fig. 1 illustrates a portable automated drywall board cutter 1 according to an embodiment of the invention seen in a perspective front/top view. The board cutter 1 comprising a housing 2 having an inlet opening 5 (see Fig. 2a) and an outlet opening 6. A dry wall board 4 to be cut can be introduced into and exit any of the two openings 5, 6. The housing is for safety reasons in an embodiment a closed cover with openings 5, 6 thereby protecting a user for getting in contact with the cutting devices.

[0106] The present dry wall board cutter 1 facilitates cutting a complete board 4 because the board enters the inlet opening 5 and exits the outlet opening 6 while the board 4 is being cut. This is advantageous in that the size of the drywall board cutter 1 can be reduced significantly in that there is no requirement for support for the board 4 while it is being cut. Further, there is no need for the cutting device 7, 8 to be able to mover across the entire area of the board 4 to be able to cut any cutting pattern in the board. The present drywall board cutter 1 is simply controlling movement in and out of the housing 2 while the board is being cut.

[0107] To increase the flexibility in cutting abilities i.e. the variations of cutting pattern and decrease speed of cutting a cutting pattern, the board can be moved both ways through the housing 2 while it is being cut. Hence, the controller 11 may control the board drives 3 to move the board from and through the inlet opening 5 towards and through the outlet opening 6 while cutting and the other way (i.e. from and through the outlet opening 5 towards and through the inlet opening 6 while cutting).

[0108] As mentioned, the board to be cut can be a complete board i.e. a standard size board having dimensions such as (width x length x thickness) 90cm x 120cm x 1,25cm and 120cm x 240cm x 1,5cm. The drywall board cutter 1 can be designed to cut boards having a width of 90cm or 120cm. The latter will also be able to cut boards having a width less than 120cm. The length does not matter in that the board is cut while being moved in / out of the housing 2.

[0109] The dry wall board cutter 1 can be designed to cut boards having any width such as below 200cm, length such as below 400cm and any thickness such as below 15cm, 10cm or 5cm. An example of thickness is a gypsum board which typical has a thickness less that 3cm, board thicker than 5cm may be made of a foam material.

[0110] A cutting pattern 25 is illustrated in the board 4 of Fig. 1. On the output side i.e. in front of the board cutter 1 of the illustrated embodiment, the cutting pattern is illustrated with a solid line 25a indicating that this part of the cutting pattern is cut in the board 4. On the back side of the board cutter 1, the cutting pattern is illustrated with a stipulated line 25b indicating that this part of the cutting pattern is not cut yet. Hence, the not yet cut part of the cutting pattern 25b is only present in the control software of the controller 11.

[0111] In an embodiment, which of the openings 5, 6 is considered input and output is defined in the software of the controller 11 controlling the board cutter 1. From a hardware point of view a board 4 can enter and exit the board cutter 1 from any of the openings 5, 6.

[0112] The weight of the housing 2 of the dry wall board cutter 1 of the present invention (including cutting drives, cutting devices, etc.) is in an embodiment less than or equal to 40Kg, 35Kg, 32Kg 25Kg, 20Kg or 16Kg. As will be explained below, board support 22 and legs 18 may be attached to or used together with the board cutter 1. The weight of these alone may in an embodiment be less than 40Kg, 35Kg, 32Kg 25Kg, 20Kg, 16Kg, 12Kg or lOKg. If desired, the board cutter 1 can be dismantled in two or more parts to reduce the weight of the board cutter 1. The individual parts of the board cutter 1, when this can be dismantled, is below 20Kg, preferably maximum 16Kg.

[0113] In an embodiment, the drywall board cutter 1 can be portable i.e. moved by lifting by one or two persons. Alternative, the board cutter 1 can be portable i.e. movable by a wheeled support. Part of such wheeled support may be lifted by a person or by a vehicle. Portable can imply that the board cutter 1 can be packed away and temporary stored in e.g. a commercial vehicle. [0114] Fig. 2a illustrates a view of the board cutter 1 from the back, i.e. from the side which in this embodiment has been assigned to be the board input side of the board cutter 1. Therefore, the opening illustrated on Fig. 2a is referred to as inlet opening 5.

[0115] Fig 2b illustrated a view of the board cutter 1 from the front, i.e. from the side which in this embodiment has been assigned to be the board output side of the board cutter 1. Therefore, the opening illustrated on Fig. 2b is referred to as output opening 6.

[0116] Note that to illustrate that the board drives 3 can be implemented as conveying elements, wheels, etc. the board drives on the inlet side of the housing 2 illustrated on fig. 2a is of a conveyer type whereas the board drives on the outlet side of the housing 2 illustrated on figure 2b is of a wheel type.

[0117] In both Fig. 2a and Fig. 2b, cutting devices 7, 8 can be seen as well as part of board drives 3 can be seen. Note that this is only for illustrative purpose and thus not limiting, the location of board drives 3 can be different and the cutting devices are moving while cutting.

[0118] A dry wall board 1 should be understood as a board typically around 2 meters in length and 90 cm or 120 cm in width depending on manufacture or application of use (these measures are only non-limiting examples). Accordingly, handling such boards day after day one person alone may lead to health problems building up over the years. The drywall cutter of the present invention automates the cutting process and thereby the unfavorable handling of boards are reduced for the work person. This is because the work person does not need to lean and force a handheld knife against the board to cut it on one or both sides.

[0119] Dry wall boards has many names including, but not limited to, gypsum board, plasterboard, wall board, white board which covers the most frequently used type of drywall board. Drywall boards comes also with moisture resistant, soundproof, fire resistant or other capabilities. Most common type is the gypsum board, but drywall boards can also be made of fibre gypsum, foam, insulating material or other materials. Generally, a drywall board is build-up of a center material enclosed or wrapped in an outer material which is different from the center material. The outer material typically introduces the strength to the drywall board hence if the center material was not enclosed in the outer material the board would be too soft or porous to be used e.g. to build a wall.

[0120] In addition, the following is a non-exhausting list of types of drywall boards which various embodiments of the board cutter 1 may be designed to cut. By design should mainly be understood as board drive type and implementation and type of cutting device. The list includes EPDM-Folie, Vinyl, linoleum, Pir and pur isulating based boards, asphalt roofing, roof membranes, installation insulation, polystyrene EPS and XPS, mineral wool, rockwool, foamboards, etc. Some of these board types may only need to be cut from one side, however in an embodiment of the present invention, the board cutter 1 facilitates cutting these boards from both sides.

[0121] Further, it should be noted that by manipulating the board inlet 19 slightly to be able to hold a reel of rolled up material, the board cutter 1 in embodiments may receive and thereby cut longer boards from such roll up.

[0122] According to an embodiment of the invention, the board cutter 1 comprises one or more board drives 3. A board drive 3 should be understood as any type of mechanism that can facilitate movement of the board 4 through the openings 5, 6 of the board cutter 1. Preferably, but not limiting, the board drive 3 facilitates moving in both directions through the board cutter 1 also during a cutting operation.

[0123] The board drive 3 may use the friction created by gravity between board drive 3 and board 4 to move the board 4. Obviously, if only one board drive 3 is present this should be a lower board drive 3a. The board drive 3 may, in addition to moving the board 4, also ensure that the bord is in an X planed which is preferably horizontal. This can be achieved either by one large lower board drive 3a extending e.g. at least 10% of the width of the inlet opening 5, by having two or three lower board drives 3a distributed along the width of the inlet opening 5 or by having a centered lower board drive 3 in combination with recesses on which the edged of the board 4 can rest as it is moved through the board cutterl. As indicated, within the scope of the invention the mechanical design ensuring that the board 4 moves through the board cutter 1 in a horizontal plane (along a first axis) is numerous. Note that the first axis may be defined as the length of the board and could also therefore be referred to as the X axis.

[0124] Note that in the horizontal embodiment (as illustrated in fig. 5) the board drives ensure that the board enters perpendicular to the opening 5 and thereby to the Y axis. To ensure this, a protrusion (passive or active) may be included in the design for guiding the board / ensuring the board is correctly introduced. The board drive may be angled and thereby push the board against the protrusion as it moves the board through the cutter 1. The protrusion may be active i.e. controllably movable and thereby push the board against a protrusion located on the other side.

[0125] In embodiments, the board cutter 1 also comprises one or more upper board drives 3b. Especially, if the board cutter is not positioned in the horizontal plane, upper board drives 3b could be necessary. Further, if the board 4 to be cut is light or small in size or both the friction established by gravity may not be enough to ensure the moving of the board at the same time as the one of the cutting devices 7, 8 is cutting the board and hence one or more upper board drives 3b may be required.

[0126] The board drive 3 refers to both active and passive drives. A passive board drive 3 is a board drive that only comprises a passive conveying element such as a roller ensuring that a board 4 is guided with as little friction as required through the board cutter 1. An active board drive 3 comprises a motor that is mechanically connected to the conveying element so as to make the conveying element rotate when the motor rotates. The mechanic connection can be with or without gears, implemented with toothed wheels, belt, shaft, spindle, etc. Hence, the active board drive is controllable by the controller 11 controlling the motor and thereby the controller 11 is able to control movement of the board along an X axis via the active board drives.

[0127] Accordingly, at least one of the board drives 3 is an active board drive. The most obvious choice is to implement an active lower board drive 3a, but the active board drive could also be an upper board drive 3b. [0128] The conveying element of a board drive 3 can be any kind of rollers or conveyer belt like elements that are suitable for being used to active or passive guide and / or move a board through the board cutter 1.

[0129] In an embodiment, board drives 3 are positioned on both sides of the one or more cutting devices 7, 8 i.e. on both sides of the Y axis defining the movement of the one or more cutting devices 7, 8 so as to facilitate moving an entire board 4 pass the cutting devices. In an embodiment, board drives 3 positioned on opposite sides of the Y axis are connected by a conveyer belt.

[0130] It should be noted that the upper and lower cut drives 9, 10 may be controlled by individual motors or by the same motor. In both cases, the motor is preferably controlled by the controller 11.

[0131] According to an embodiment, the board cutter 1 comprises at least one cutting device and thereby facilitating cutting on only one side of the board 4. However, in a preferred embodiment for gypsum boards, the board cutter 1 comprises two cutting devices an upper cutting device 7 and a lower cutting device 8 and thereby facilitating cutting on both sides of the board 4. By cutting on both sides, the work person that is going to mount the cutting 13 after it is cut / separated from the board does not need to perform anything else but breaking the board along the cutting pattern. Further, cutting both sides of the board ensures a “clean break” or “controlled break” that does not leave broken parts of the on the board or cutting.

[0132] A cutting device that should not cut completely through the board 4, is preferably implemented as either a blade such as a knife blade having a cutting edge or as a rotary cutting tool both of which that can be dragged or pushed to establish a cutting pattern in the board. If a complete cut through the board in a cutting pattern is required, an alternative is to use a cutting device in the form of a tangential knife.

[0133] The number of cutting devices may depend on the type of drywall boards to be cut. A board cutter 1 may be designed to cut a specific type of dry wall board. For gypsum boards preferably both an upper and a lower cutting device is used to avoid post cut work such as cutting cardboard on the non-cut side. Drywall board cutters 1 designed specific for cutting e.g. foam-based or insulating material based boards may only comprise one cutting device such as an upper or a lower cutting device.

[0134] The type of cutting device may depend on the type of drywall board. If foambased boards are to be cut, the cutting device(s) may be implemented as pizza knife like cutters i.e. a cutting wheel whereas gypsum boards are typically cut by knifes, rotating wheel knifes or toothed knife wheels.

[0135] In an embodiment, the board cutter may have more than one upper and / or more than one lower cutting device such as both a drag knife and a rotating cutter or a milling tool.

[0136] In an embodiment, where material should be moved, a milling tool is preferred. This may be relevant e.g. to facilitate space for spackling of two adjacent boards on a wall. This could be facilitated by removing board material by a milling tool.

[0137] In the embodiment where the cutting device is a knife blade, the blade may be a standard blade with recesses to positioning the blade in a connector block. The controller may determine when it is time to replace the blade e.g. if a current consumption of the motor moving the blade increases as an indication of a blunt blade. Alternatively, a sensor may inspect frayed edges e.g. by visual sensors. Alternative, a blunt knife blade tends to leave the board and thereby movement of the blade along the Z axis may also indicate that it is time to replace the blade.

[0138] The cutting device is part of a cut drive 9, 10, which comprises means for releasably fastening the cutting device. Hence, it is possible to replace the cutting device when this is blunt / worn out. The means for fastening could be implemented as connector block having screws forcing two plates together against the blade or similar fastening systems known to the skilled person.

[0139] A connector block for holding a cutting device is connected to a drive mechanism that, controlled by a motor / controller 11, is movable along the Y axis as described above. [0140] The drive mechanism facilitating the movement of the cutting device along the Y axis may be linear drive, threated rod, belts / belt drives, rack or similar mechanical mechanisms. Such drive mechanisms may be controlled by a motor via the controller 11.

[0141] As mentioned, the board cutter 1 comprises a controller 11 that is configured for controlling the different drives and thereby movement of the board 4 and the cutting devices 7, 8 according to a cutting pattern established based on measurements provided to the controller 11 from a user. The controller 11 controls the board drives 3 to move the board along the X axis. Perpendicular to the X axis and thereby the movement of the board 4, the controller controls the cut drives 9, 10 to move the cutting devices 7, 8 along the Y axis. Hence, by coordinating the movement of board 4 and cutting devices 7, 8 any desired cutting pattern can be made in the board 4.

[0142] More specifically, input is provided to the controller from a portable user device 16 handled by the user. Input from the portable user device, which may be a tablet or smartphone, is typically length information i.e. measures defining the size / geometric shape of the required cuttings 13 and thereby defining the cutting pattern 25 to be cut in the board 4.

[0143] Further, the controller 11 may receive input from sensors. Sensors may provide information of if a board 4 is positioned in or in proximity of the board cutter 1, if the board is positioned correct inside the cutter 1, etc. Further, sensors may be used for calibration of the start position also referred to as homing, indicate if feeder / board storage is loaded with boards, safety, encoder, switches, readers, etc.. Further, the controller 11 may receive input from push buttons such as emergency stops, start / stop, manual forward / back buttons, etc.

[0144] One way for the cutter 1 to determining where the board is, is to use a combination of one or more sensors and an encoder. The counting of the encoder may be corelated with the signal from a sensor indicating the position of the end of a board. In this way e.g. by moving the board forth and back, the controller may determining the position of the board. [0145] The controller 11 which may be a standard industrial PLC (PLC; Programmable Logic Controller) comprises a computer control program that processes the input and based thereon establishes output that is used to control motors of the board cutter 1.

[0146] In an embodiment, the control program comprises different predefined cutting offs for the most common cuttings 13. Hence, the user selects a predefined cutting off and the controller prompts the user to input measures required for / defining the chosen cutting off. The controller then translates the cutting off now with measures to a cutting pattern 25 and controls the drives 7, 8, 9, 10 accordingly, thereby establishing a cutting that reflects the cutting off with measures.

[0147] Fig. 3 illustrates a schematic cross-sectional view of the board cutter of Fig. 1 at the line A. As can be seen, this embodiment of the board cutter 1 comprises to two upper and two lower board drives 3 located on each side of the upper and lower cutting devices 7, 8. Also illustrated, is the controller 11 communicating with the portable user device 16 and drivers 3, 9, 10. In this embodiment, both the upper and lower cutting devices 7, 8 are cutting i.e. the board 4 is cut on both sides.

[0148] The illustrated position of the knives indicates that they are drag knifes and that they are not moved while the board 4 is moved in the direction of the arrow. In this view, the board is moved in direction of the arrow at the same time as the cut drives 9, 10 are moving the cutting devices 7, 8 i.e. the knifes is seen in a slanting view. If the board were not moved and the cutting devices were moved, the knifes would have been seen only as a line indicating one of the edges of the knifes (as in fig. 2a ad 2b).

[0149] It should be mentioned that in an embodiment, the cutting devices 7, 8 are of the drag knife type as described above i.e. following the movement of the board 4, the cut drives 9, 10 or a combination of movements hereof. The movement of the drag knife is in the direction parallel to the inlet opening 5 and rotation around the Z axis.

[0150] It should be mentioned that the cutting devices 7, 8 may also be implemented as alternatives to drag knifes. No matter the type of the cutting devices 7, 8 the rotation of the cutting devices 7, 8 may be controlled by the controller 11. Controlling rotation of the cutting devices 7, 8 may require an upper and a lower Z axis rotation drive (not illustrated). Such drive can be implemented as a servo drive controlling a threaded rod, mechanical connections such as tooth wheel, belt pulley, spindle or similar.

[0151] Having an upper and a lower cutting device 7, 8 is advantageous in that the pressure / force applied from these to the board 4 are opposite. Hence there is no need for a supporting structure on the side of the board 4 opposite to the cutting device.

[0152] The force applied from the cutting devices 7, 8 may be adjusted and may not necessarily need to be the same on both sides. It is preferred, that when the drywall board cutter 1 is cutting a gypsum board, the cardboard layer of a gypsum board on both sides are cut. The controller 11 may further adjust one or both of the cutting devices 7, 8 to also cut in the gypsum.

[0153] In fig. 3, the board drives 3 on the inlet side are illustrated as active drives connected to a motor 17. The board drives 3 on the outlet side are illustrated as passive drives. This is to illustrated that both active and passive board drives may be used knowing that in an embodiment it is preferred to have active board drive on both sides of the cutting devices to be able to move the board out of the housing 2.

[0154] In an embodiment, the cut drives 9, 10 may facilitate locking the cutting devices in a desired angular position. The angular position could be with reference to the direction of movement of the board i.e. the X axis or with reference to the Z axis the is perpendicular to both the X and Y axis. If the cutter is able to rotate the cutting devices e.g. 180 degrees around the Z axis (either by means of a motor or by coordinated movement of the board along the X axis and the cutting device along the Y axis) the board may need to be moved forth and back more than if the cutting devices are able to rotate e.g. 360 degrees around the Z axis.

[0155] In the embodiment where the cutting device(s) is not able to rotate 360 degrees, the cutting devices may need to be movable along the Z axis. Such movement could be facilitated by a camshaft, an actuator, a magnet or the like. Note that moving the cutting devices may also be relevant and possible in the embodiment where the cutting device(s) is able to rotate 360 degrees.

[0156] Further, in an embodiment, the cut drives 9, 10 may facilitate moving the cutting devices 7, 8 along the Z axis so that the board can be moved through the board cutter 1 without being cut. This is relevant if the board cutter has two cutting devices and only needs to be cut at one side or if e.g. a hole has to be cut in the board 4 which is not connected to an edge or other cuts of the board 4 (see Fig. 4).

[0157] The locking of a cutting device can be made manually at the drive or connector block or automatically by a motor implemented to control rotation around the Z axis. In the same way the movement of the cutting device along the Z axis can be made by a motor implemented to control this movement. Such motor may control a threaded rod via which the connector block is connected to e.g. a liner drive. Note that the motor controlling the position along the Z axis e.g. via a threaded rod may also control the angle of the cutting device with respect to the Z axis.

[0158] The dept of the cut in the board, when the board is a gypsum board only needs to be a few millimetre. In fact, it only needs to cut through the outer layer to facilitate breaking of the board by a work person. Performing such fine cut only in the outer layer manually is difficult especially for the untrained work person. Therefore, the manual handled knife becomes blunt faster than a similar knife use by the board cutter in that the precision of the board cutter is more accurate each time it cuts. .

[0159] Hence, in a gypsum board the depth of the cut may be less than 2 millimetre such as between V > and Vi millimetre corresponding to the thickness of the outer layer of cardboard of a gypsum board.

[0160] For other types of boards such as foam boards (including Polyethylene boards and similar) the depth of a cut needs to be deeper. In fact, the cut may go all the way through the board. [0161] To be able to cut different types of boards, the pressure with which the cutting device is forced into the board is adjustable. The pressure may be manual or automatic adjustable.

[0162] If the cutting pattern does not start at an edge of the board and the cutting device is e.g. a drag knife, the movement of at least the board or the cutting device along the Y axis simultaneously with movement of the cutting device along the Z axis is preferred to avoid pushing / squashing the knife into the board rising damaging the knife or board and applying unmercenary load to the elements of the board cutter 1.

[0163] Fig. 4 illustrates a surface 12 in the form of a wall that is to be covered by gypsum boards. As illustrated part of the wall 12 is covered by complete / whole gypsum boards 13a and parts are covered by gypsum board cuttings 13b. The cutting off parts 13b are automatically cut by the board cutter 1 of the present invention.

[0164] From this figure it is visual that the measures for the width of a cutting 13b is measured at the wall 12 between e.g. as the distance between an edge of a gypsum board and a door opening whereas the length of the cutting 13b is an entire board length. The stipulated line denoted 13a illustrates the coverage of a complete board, which as illustrated covers the door opening if not cut. Hence, the user now can measure either the part that should be removed from the board or the part that should after the cut should be the cutting 13b that is to be mounted on the wall 12. The measures to take may depend on the cutting off / geometry of the desired part of the board to be used and via which the measure(s) in an embodiment are provided to the board cutter controller 11.

[0165] Hence the user selects a “length cutting off’ and enters the desired width of the cutting in the graphical user interface / application (APP) associated with the board cutter 1 of the portable user device.

[0166] Before the cut is initiated, the portable user device may remind the user to place a board so that the board drive 3 can move the board, ask for acknowledge / approval of a visualisation of the cutting displayed on the user device 16, place a board so that it engages with the board drive, etc. [0167] Fig. 5 illustrates a board cutter system comprising a stack of boards 20 that is ready to be cut. Such stack 20 is typically resting on a pallet or transverse lumber to be able to be moved by a pallet truck, not to be damaged by water if water is on the flow, to be able to easier lift the lower most board in the stack, etc. The pallet or transverse lumber including the stack 20 may be referred to as a board feeder 19.

[0168] The purpose of the board feeder 19 is to align the upper most board of the stack 20 with the inlet opening 5 of the board cutter 1. This can be facilitated either by changing the height of the upper board or by changing the height of the inlet opening 5. The former can be facilitated by a mechanical device that is raising the stack 20 with the hight of one board thickness as a board is cut. The latter can be facilitated by adjusting length of legs 18 of the board cutter 1.

[0169] In an embodiment, the legs are adjustable and hence when a board 4 is cut, the length of the legs 18 is reduced with the thickness of the board. This may be controlled by the controller 11. Preferably the board feeder 19 in such embodiment ensures the lower most board is positioned in the same plane as the inlet opening, when the legs 18 are at its lowest height.

[0170] Fig. 5 also illustrates a board support 22 that support the board 4 that is cut when it exits the board cutter 1. A board support 22 could be a table or a stack of boards (if the cut board exits the board cutter at the opening it entered, the stack 20 could work as board support 22). In the illustrated embodiment, the board support 22 is a horse like structure the height of which is aligned with the outlet opening 6. Even if the board when cut exits through the inlet opening 5, it may need support during to cutting operation. The board support 22 may comprise a passive conveyer element 24 on its top.

[0171] The board cutter 1 and the board support 22 may be connected by a support beam or guide 23 ensuring support of the board as it exits the outlet opening 6. It is preferred that the board support is in the same plane as the cutter 1 to avoid braking of the board as it leaves the cutter 1. [0172] In an embodiment, the horizontal system illustrated on fig. 5 is tilted enough to ensure that gravity forces the board down towards lower part of the board cutter. In this way it is ensured, that the board is always entering the board cutter at the same “Y value”. In this way, active board drive may only be needed in the lower part of the board cutter whereas board drives (if any) in the upper part of the board cutter may only be passive i.e. only supporting or guiding the board.

[0173] In an embodiment, the board cutter is attached to the stack of boards and instead of moving the board through the board cutter, the board cutter is moving over the board. This embodiment reduces the required area of operation of the board cutter, while it mads the mechanical design a bit more complicated. The mechanical design would require beams along the stack facilitating movement of the board cutter along the X plane. Further, in order to cut on both sides, the board needs to be spaced from the boards of the stack.

[0174] Fig. 6 illustrates an embodiment, where the board cutter 1 is tilted so that it stands upright in a substantial vertical position. The above description, where some is directed to a horizontal positioned cutter, may apply to the vertical embodiment illustrated on fig. 6 and 7. Substantial vertical should be understood as an angle to horizontal which is 90 [deg.] or below 90 [deg.], preferably between 45 and 85 [deg.] most preferably between 55 and 80 [deg.] measure from horizontal. An angle of 75 [deg.] may be preferred in that a board feeder then is able to hold boards by means of gravity force whereas 90[deg.] may required manual handling of a board that is to be introduced into the cutter.

[0175] In a vertical system as illustrated fig. 6, the board cutter 1 may be mechanically connected to a board feeder 19, comprising a stack of boards 20. Such mechanic connection may ensure alignment between feeder 19 and cutter 1. Note that the vertical positioned cutter 1 may also stand and work alone without a board feeder 19. In a simple embodiment, the board feeder may be a simple resting piece aligned in height with the inlet opening 5 to assist the user in introducing the board 4 into the inlet opening 5 in a substantially perpendicular direction (X plane) relative to the movement of the cutting device (moving in Y plane). [0176] The mechanical connection 26 may be simple beam connecting the cutter 1 and the feeder 19 by bolt and nuts, quick locks or similar. The mechanical connection may include an upper connection (illustrated) and / or a middle connection and / or a lower connection. The middle or lower is not illustrated due to the board to be cut 4. Instead of a beam connection as illustrated, the mechanical connection may also be implemented as a rack connected to the board feeder 19 on which the cutter 1 can subsequently be mounted. If the mechanical connection is not connected to a board storage 21, it may require a leg or the cutter 1 may require a leg to assist the board feeder 19 in carrying the weight of the cutter 1.

[0177] In an embodiment, the mechanical connection may also facilitate moving the cutter 1 in the Z direction so as to facilitate automatic alignment of the board to be cut 4 next in the stack of boards 20 with the inlet opening.

[0178] A board 4 is illustrated as halfway through the cutter 1 partly resting on the feeder 19 and on a board storage 21. The cutter 1 may have legs 18 but may also completely be fixed by the board feeder 19 and board storage 21 (if present) which in combination then carries the weight of and potions of the cutter 1.

[0179] The board feeder and storage 19, 21 may be a standard board trolley which may be pivotable, have legs with or without wheels. As mentioned above, the feeder and storage 19, 21 may be simple (adjustable) tables or supports / horses.

[0180] Fig. 7a illustrates the board cutter 1 in an inlet side view in a vertical embodiment of the cutter 1. As seen the same cutting devices 7, 8 are used but in contrary to the horizontal embodiment, the board drive 3 is positioned at the lower end 5a of the inlet 5. From the view illustrated on fig. 7a only one board drive 3 is visible, but preferably multiple board drives through the cutter 1 is present as will be explained in detail in relation to fig. 7b. Note that the X plane is into the figure.

[0181] Fig. 7b illustrates the inside of a board cutter housing 2 used in a vertical embodiment when the front cover 2a (illustrated on fig. 6) is removed. The board 4 is resting on lower board drives 3a and in this particular embodiment, upper board drives 3b are also included. As in the horizontal embodiment of the board cutter illustrated in figs 2a, 2b and 3, the upper board drives 3a may not be necessary. Returning to the vertical embodiment of figs. 6, 7a and 7b the lower board drives are preferred as gravity forces the board 4 down towards the lower board drives 3a.

[0182] The lower (and the upper) board drives 3a may include both passive and active board drives. The active board drives in this particular embodiment includes board drive springs 27 to ensure sufficient connectivity / friction between the active board drives and the board to ensure movement of the board 4 through the housing 2. When there is no board in the housing, the active spring actuated board drives are lifted above the level of the passive board drives by the springs 27.

[0183] The upper cut drive 9 is in this embodiment illustrated as movable via a belt engaging with shafts or bearings in the upper and lower part 5a, 5b of the housing 2. At least one of these shafts or bearing is driven by a motor e.g. directly or indirectly via another not illustrated belt to a motor. This motor may also drive another element of the cutter 1 such as active board drives the lower cut drive 10, etc. Together, the shaft, motor and belt are all together referred to as cut drive 9. The cut drive also includes a not illustrated connector block for connecting a cutting tool. This would be located in the box part of the illustrated upper cut drive 9 as will the parts necessary for being able to move the cutting tool (cutting device) along the Z axis. The Z axis in fig. 7b is into the figure.

[0184] From the above, it is now clear that the present invention relates to a drywall board cutter 1 that can cut drywall boards one at the time that are introduced into the cutter 1 in a plane that in an embodiment is perpendicular to the cutter housing 2. The orientation of the housing 2 can be from horizontal to vertical without the need of changing anything to the cutter design. With this said the board drive design may be changed in dependence of if the preferred use of the board cutter is e.g. substantially vertical or substantially horizontal.

[0185] In an embodiment, the cutter 1 comprises both an upper and a lower cutting device 7, 8. These cutting device may be implemented as drag knifes cutting through at least the outer layer of one or both sides of a drywall board. In other embodiments, the cutting device may be a rotating cutting device which may cut all the way through or at least almost all the way through the drywall board. In yet another embodiment, the upper and lower cutting devices 7, 8 are not the same so that e.g. the upper cutting device is a rotating slicer cutting almost all the way through the board and the lower cutting device is a knife which only cuts the outer layer of the board or vice versa.

[0186] The cutting devices 7, 8 are controlled by cut drives 9, 10 which are implemented as mechanical linear, shaft, belt, etc. drives moving a connector block in which the cutting device is releasable fastened. The cut drives and board drives are controlled by a controller which communicates with a user preferably via a portable user device. The user uses the portable user device to provide measures to the controller. The measures are in an embodiment associated with a cutting patter or defines a cutting pattern in which the board should be cut.

[0187] In embodiments, the cutter 1 is connected to or located adj acent or one or both of a board feeder 19 or board storage 21. In this way is it is easier for the user to input the boards into the inlet 5 substantially perpendicular to the inlet opening 5 and the user does not necessarily need to way for the board to be cut in that it is received by the board storage when cut.

[0188] Finally, is should be noted, that the cutter 1 may comprise only one of the upper and lower cutting device 7, 8 i.e. only comprising one cutting device. This is especially relevant for cutting of foam type dry wall boards and gypsum boards where for some reason the outer layer of one side of the board does not need to be cut. With this said via control of a cutter 1 having two cutting devices, only one can be used.

[0189] Note, that when referring to the X, Y, Z plans in the horizontal system illustrated on fig. 5, the X plane is defined as the horizontal plan i.e. plane in which the board is introduced into the board cutter. Therefore, when moving the board along the X axis / first axis the movement of the board is in and out of the board cutter 1. The Y plan is defined as the plan perpendicular to the X plan (since Fig 5 is 2D the Y plan extents “into the drawing” and is therefore not illustrated). Therefore, moving the cutting devices along the Y axis / second axis is a movement perpendicular to the length of the board. In the same way the Z plane is perpendicular to both the X and Y plans and a movement of the cutting device along the Z axis / third axis is a movement towards or away from the side of the board.

[0190] In the vertical system illustrated on fig. 6, the X, Y, Z plans are turned with the board cutter. Therefore, the X plane / first plane is still the plane in which the board is introduced into the board cutter, the Y plane is perpendicular to the X plan and the Z plan is perpendicular to both the X and Y plans i.e. the Z plane is horizontal, if the cutter is positioned vertical.

List

1. Drywall board cutter

2. Housing

3. Board drive

4. Drywall board

5. Inlet opening

6. Outlet opening

7. Upper cutting device

8. Lower cutting device

9. Upper cut drive

10. Lower cut drive

11. Controller

12. Surface

13. Cutting

14. Fasteners

15. Drive part

16. Portable user device

17. Motor

18. Legs

19. Board feeder

20. Stack of drywall boards

21. Board storage

22. Board support

23. Board guide

24. Conveying elements

25. Cutting pattern

26. Mechanical connection

27. Board drive spring

Claims

37 Patent claims

1. A portable automated drywall board cutter (1) comprising a housing (2) having at least one board drive (3) configured for moving a board (4) along a first axis through a board inlet opening (5) and out of a board outlet opening (6) of the housing (2) while cutting, an upper cutting device (7) and a lower cutting device (8) is positioned between the board openings (5, 6) and is configured for cutting the board, the cutting devices (7, 8) are movable along a second axis by an upper cut drive (9) and a lower cut drive (10) respectively, wherein the control of the cutting drives (9, 10) and thereby the movement of the cutting devices (7, 8) along the second axis and the control of the at least one board drive (3) and thereby the movement of the board (4) along the first axis is automatically coordinated by the controller (11) so as to facilitate coordinated movement of the board (4) and the cutting devices (7, 8) according to a cutting pattern.

2. A portable automated drywall board cutter (1) according to claim 1, wherein the first axis is in a horizontal plane, in a vertical plane or in a plane therebetween.

3. A portable automated drywall board cutter (1) according to claim 1 and 2, wherein the cutting pattern is cut in both sides of the dry wall board (4).

4. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the drywall board cutter (1) is configured to move the drywall board (4) both into and out of the inlet opening (5) during the same cutting operation.

5. A portable automated dry wall board cutter (1) according to any of the preceding claims, wherein a portable user device (16) is configured for receiving measures of the cutting pattern via predetermined cutting offs.

6. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the upper cut drive (9) and a lower cut drive (10) are independently controllable. 38

7. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the upper cut drive (9) and the lower cut drive (10) facilitates moving the upper and lower cutting devices (7, 8) along a third axis.

8. A portable automated dry wall board cutter (1) according to any of the preceding claims, wherein each of the upper and lower cut drives (9, 10) comprises fasteners (14) configured for fastening the cutting devices (7, 8) to a drive part (15) and a motor configured to move the drive part along the second axis and thereby the cutting devices along the (7, 8) along the second axis.

9. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein at least one of the fasteners (14) is configured to lock the associated cutting device (7, 8) in an angle around the third axis.

10. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the cutting devices (7, 8) are rotatably mounted so as to facilitate rotation of at least 180° [deg], preferably 360° [deg] around the Z axis.

11. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein force is applied to the upper and lower cutting devices (7, 8).

12. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the same force is applied to the board (4) from the upper and lower cutting devices (7, 8).

13. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the upper and lower cutting device (7, 8) are selected from the list comprising: knife, drag knife, tangential knife, wheel cutter, milling tool and toothed wheel cutter.

14. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the controller (11) is configured to add an offset to the cutting pattern if the cutting pattern includes a curve.

15. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the at least one board drive (3) is configured for moving the board (4) along the first axis by a conveyer element mechanically connected to a motor (17).

16. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the at least one board drive is a lower board drive (3a) and wherein the drywall board cutter (1) further comprises at least one upper board drive (3b).

17. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the board drives (3) comprise a conveyer element.

18. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the conveyer element is mechanically connected to a board drive motor (17).

19. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the direction of rotation of the motor(s) (17) is controllable by the controller (11) according to the cutting pattern.

20. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the drywall board cutter (1) comprises a least two active board drives (3).

21. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the controller (11) facilitates coordinated control of the upper and lower cut drives (9, 10) and of the board drive (3) so that the board (4) is moved along the first axis simultaneously with movement of the upper and lower cutting devices (7, 8) along the second axis and third axis.

22. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the controller (11) and the portable user device (16) is configured to communicate wirelessly.

23. A portable automated drywall board cutter (1) according to any of the preceding claims, wherein the drywall board cutter (1) is configured for cutting a gypsum board comprising a gypsum layer sandwiched between two cardboard layers and wherein at least one of the cutting devices (7, 8) only cuts through one of the cardboard layers.

24. A method of cutting a drywall board (4), comprising the steps of: a) establish a cutting pattern, reflecting at least part of a surface (12) to be covered by one or more drywall board cuttings (13), on a portable user device (16), b) provide the cutting pattern to a controller (11) of a drywall board cutter (1), c) initiate the cutting of the board (4), d) by the controller (11):

- control a board drive (3) and thereby movement of the board (4) through a board inlet opening (5) and a board outlet opening (6) of a housing (2) in a first direction, and

- control at least one of an upper cut drive (9) mechanically coupled with an upper cutting device (7) and a lower cut drive (10) mechanically connected to a lower cutting device (8) and thereby movement of at least one of the upper and lower cutting devices (7, 8) in a second direction, wherein the control of movements of the board (4) and cutting devices (7, 8) is automatically coordinated to cut the cutting pattern in the board (4) while the board enters the board inlet opening (5) and exits the board outlet opening (6).

25. A method according to claim 24, wherein the method is implemented in a portable automated drywall board cutter (1) according to any of claims 1-23.

26. A method according to claim 24 and 25, wherein the first direction is perpendicular to the width of the inlet opening (5) of the housing (2).

27. A method according to any of the claims 24-26, wherein the second direction is parallel to the width of the inlet opening (5).

28. A method according to any of the claims 24-27, wherein the measures of a desired cutting pattern are communicated wirelessly to the controller (11) via the portable user device (16).

29. A method according to any of the claims 24-28, wherein the cutting is initiated wirelessly by a user via the portable user device (16).

30. A method according to any of the claims 24-29, wherein at least two cutting patterns are communicated to the controller (11) and wherein the controller (11) is nesting the at least two cutting patterns.

31. A method according to any of the claims 24-30, wherein at least one of the cutting devices (7, 8) is marking the cuttings (13).

32. A method according to any of the claims 24-31, wherein the board cutter (1) comprises a marker, and wherein the board cutter (1) is marking cuttings (13) with the marker.

33. A method according to any of the claims 24-32, wherein the establishing of a cutting pattern is made based on predefined cutting off.

34. A method according to any of the claims 24-33, wherein the method further comprises the step of providing board thickness to the controller (11).

35. A method according to any of the claims 24-34, wherein the method further comprises the step of providing information to the controller (11) that a board has been removed from a stack of boards.

36. A method according to any of the claims 24-35, wherein the method furthermore comprises the step of adjusting height of the inlet opening (5) of the portable automated panel cutter (1).

37. A method according to any of the claims 24-36, wherein the height of the inlet opening (5) is adjusted by adjusting length of legs (18) of the portable automated panel cutter (1). 42

38. A drywall board cutter system comprising a portable automated drywall board cutter (1), a board feeder (19) and a board storage (20), wherein the drywall board cutter (1) comprising a housing (2) configured for receiving a board (4) through a board inlet opening (5) and exit the board through an outlet opening (6) while cutting, between the board openings (5, 6) at least an upper cutting device (7) is positioned, the cutting device (7) is controlled by an upper cut drive (9), the cut drive (9) include a motor controllable by a controller (11), wherein the board feeder (19) is configured to provide the upper board of a stack of drywall boards (20) to be cut to the inlet opening (5) in a first plan, and wherein the board storage (21) is configured to receive boards, that are cut, from the outlet opening (6) in the first plan.

39. A drywall board cutter system according to claim 38, comprising a drywall board cutter (1) according to any of the claims 1-23 and controlled according to a method of any of the claims 24-37.

40. A drywall board cutter system according to claim 38 and 39, wherein the board feeder (19) comprises a stack of drywall boards (21) to be cut, wherein the stack of drywall boards (21) comprises at least two drywall boards (4).

41. A dry wall board cutter system according to any of the claims 38-40, wherein height of legs (18) of the board cutter (1) is adjustable to facilitate continuous introduction of the upper board from the stack of drywall boards (20) into the inlet opening (5).

42. A drywall board cutter system according to any of the claims 38-41, wherein the board feeder (19) comprises a mechanic spring arrangement automatically ensuring substantially the same height of the upper board from the stack of dry wall boards (20) as boards (4) are removed from the stack of drywall boards (20).

43. A dry wall board cutter system according to any of the claims 38-42, wherein the board feeder (19) is at least partly implemented as a pallet. 43

44. A drywall board cutter system according to any of the claims 38-43, wherein the board storage (21) comprises at least one board support (22).

45. A dry wall board cutter system according to any of the claims 38-44, wherein the board storage (21) comprises at least one board guide (23).

46. A drywall board cutter system according to any of the claims 38-45, wherein the board support and / or the board guide comprises conveying elements (24).

47. A drywall board cutter system according to any of the claims 38-46, wherein the height of the board support (22) is adjustable.