Device, system, jig and method for cutting worktops

Abstract

The disclosure relates to a device 1, 101 for aligning a jig 20 with a workpiece to be cut, the device 1, 101 comprising an engagement edge 2, 102 for engaging with a guiding edge 26 of a jig 20, in use, and an alignment indicator 6, 106 spaced from the engagement edge 2, 102 by a predetermined distance. The disclosure further relates to a jig 20 comprising a device 1, 101 having an alignment indicator 6, 106 spaced from a guiding edge 26 of the jig 20 by a predetermined distance. The disclosure further relates to an alignment system and method of forming a cut on a workpiece.

Description

[0001] The present invention relates generally to the field of jigs for forming cuts in workpieces router jigs and more particularly, but not exclusively, to router jigs for forming corresponding male and female cuts in cooperating worktop pieces ('workpieces') to allow the workpieces to be joined with a Mason's Mitre joint.

[0002] When installing worktops / countertops / work surfaces (e.g. in kitchens and bathrooms) it is common practice to incorporate a joint (a 'Mason's Mitre') when connecting two lengths of worktop material in a generally perpendicular arrangement (e.g. to navigate internal corners or when installing a breakfast bar / peninsula). The Mason's Mitre is constructed by cutting a recess ('female') in one workpiece, and a corresponding protrusion (`male') in the other.

[0003] A Router, Router Cutter, Guide Bush, and Routing Jig / Template is typically used to achieve the necessary cuts in both lengths of material.

[0004] The Mason's Mitre is required in order to remove the rounded 'Postformed Edge' of worktop material, particularly common in laminated chipboard, to achieve a practical, visually appealing finish. Traditionally, the depth of the Female recess (the 'Inset') is approximately 35mm, in order to be larger than the Postformed Edge. Due to changes in worktop styles and manufacturing techniques (namely a reduction in the size of the Postformed Edge), it is now desirable to have different Inset depths available, such that less time is required to remove less material when forming the Masons Mitre.

[0005] The length of the Female recess (`Backset') is relative to the width of the Male workpiece.

[0006] The Female recess is always cut parallel to the Postformed Edge of the Female workpiece.

[0007] If adjoining walls are positioned at 90 degrees, the Male protrusion is cut at 90 degrees to the Female recess ('Square').

[0008] If adjoining walls are not positioned at 90 degrees, the Male protrusion is cut at a corresponding angle to the Female recess ('out-of-square'). The length of the male protrusion will also be determined, in part, based on the angle of the male workpiece relative to the female workpiece.

[0009] Forming complementary cuts in male and female workpieces can be a complicated task, with any misalignment between the mating edges of the workpieces resulting in an unsatisfactory finish due to e.g. gaps between the workpieces, particular at the front visible edges. Incorrect cuts may lead to workpieces being scrapped, which can be costly. Correct alignment of the cuts forming the mating edges of the workpieces is made particularly complicated in out-of-square arrangements, since the cut must be made at the correct angle to match the angle of the recess formed in the female workpiece relative to a wall against which the male workpiece is to be placed.

[0010] The present invention seeks to provide a jig that is suitable for use in reliably and accurately forming a male protrusion in a workpiece at an appropriate angle and of the appropriate dimensions to match a female recess in a cooperating workpiece, regardless of the angle between adjacent walls against which the respective workpieces are to be placed.

[0011] According to a first aspect of the present invention, there is provided a device for aligning a jig with a workpiece to be cut, the device comprising an engagement edge for engaging with a guiding edge of a jig, in use, and an alignment indicator spaced from the engagement edge by a predetermined distance in a direction perpendicular to the engagement edge.

[0012] A jig used for forming corresponding male and female cuts for a mason's mitre joint generally comprises a guide channel having one or more guiding edges for guiding a cutting tool. The or each guiding edge typically has a first straight section and a second straight second arranged at an angle relative to the first straight section, such that cutting a workpiece by guiding a cutting tool along the guiding edge forms a cut in a workpiece that has corresponding first and second straight parts arranged at angles relative to each other. This cut forms either a male protrusion or a female recess in the workpiece, depending on the orientation of the jig and the shape of the guiding edge of the guide channel that is used to guide the cutting tool (i.e. whether the two straight sections of the guiding edge have an obtuse angle or a reflex angle therebetween).

[0013] It is to be understood that the term "arranged at an angle" as used throughout the present specification refers to a non-parallel arrangement of the components or features. Where components or features are stated to be "arranged at an angle", it is preferable that the components or features are arranged at an oblique angle relative to each other.

[0014] In use, a blade of the cutting tool (i.e. a router blade) will be offset from the guiding edge of the guide channel. That is, the blade itself may not run along the guiding edge during a cutting operation. Instead, the blade may be spaced from the guiding edge by a predetermined distance that is determined, for example, by a guide bush arranged to hold the cutting tool and to be received within the guide channel, as well as the size (diameter) of the cutting blade. It is therefore important that the guiding edge of the guide channel is offset from the position of the cut by the correct distance to ensure that the cut is formed in the desired position.

[0015] With the arrangement of the present invention, the alignment indicator can be aligned with an appropriate portion of a reference mark that is provided on a workpiece to indicate a line of cut. The engagement edge of the device engages with a guiding edge of the jig and, since the alignment indicator is spaced from the engagement edge by a predetermined distance, the alignment indicator can be used to offset the guiding edge of the jig from the reference line by an appropriate distance, depending on the particular equipment being used. The device therefore provides a convenient means for accurately positioning the guiding edge of a jig relative to a desired line of cut (indicated by a reference line marked on the workpiece), such that when a cut is performed by guiding a cutting blade (e.g. a router blade) along the guiding edge, the cutting blade forms a cut along the desired line of cut. The user can therefore mark a reference line on the workpiece indicating where the cut is to be formed, and the jig can be quickly and easily positioned to provide the desired offset between the guiding edge and the line of cut, without the need for the user to derive a secondary reference line offset from the desired line of cut by the appropriate distance. Ease of use is improved and, importantly, errors due to incorrect calculations or measurements can be avoided.

[0016] In the present invention, the alignment indicator may be any appropriate indicator that provides a reference point with which the user can align the device relative to a reference point marked on a workpiece.

[0017] Preferably, the alignment indicator extends parallel to the engagement edge of the device. This improves the accuracy of the alignment compared to, for example, an alignment indicator in the form of a single point. In particularly preferred embodiments, the alignment indicator is an alignment edge of the device that is parallel to the engagement edge and spaced from the engagement edge by a predetermined distance in a direction perpendicular to the engagement edge. The alignment indicator may alternatively comprise a plurality of alignment points, each spaced from the engagement edge by the predetermined distance, such that alignment of all of the alignment points with a linear reference line marked on the workpiece ensures a parallel alignment of the engagement edge of the device with the linear reference line. The alignment indicator may also comprise an alignment mark provided on a transparent component of the device, such that a reference line marked on a workpiece underlying the device is visible through the transparent component, to allow alignment of the alignment mark with the reference. Other suitable arrangements of the alignment indicator are conceivable.

[0018] The device may comprise a first section in which the engagement edge defines a linear portion, and in which the alignment indicator is spaced from the linear portion of the engagement edge by the predetermined distance, and a second section in which the engagement edge defines a further portion that is not parallel with the linear portion of the engagement edge, and in which the alignment indicator is spaced from the further portion of the engagement edge by the same predetermined distance. In the context of the present invention, it is to be understood that the linear portion is a portion that lies on a single (straight) axis, and the further portion is a portion that does not lie on the same single (straight) axis. The further portion may be linear, extending along a different axis, or may be curved, or both.

[0019] As discussed above, the guiding edge of a jig used to form a Mason's Mitre joint will normally comprise a first (normally longer) straight section and a second (normally shorter) straight section arranged at an angle relative to the first straight section. The guiding edge is normally curved between the two straight sections. Depending on the dimensions of the cut to be made in the workpiece, the guiding edge could conceivably comprise only a straight section and a curved section. With the above arrangement of the present invention, the engagement edge of the device comprises a linear portion that can be engaged with the first straight section of the guiding edge, and a further portion that is not parallel with the linear portion, and which can be engaged with either a second straight section of the guiding edge, or a curved portion of the guiding edge, or both. Suitable positioning of the device relative to the guiding edge is thereby ensured.

[0020] At the same time, the alignment indicator provides a reference point or mark that is spaced from the engagement edge, and therefore from the guiding edge of the jig, in both sections of the device (i.e. at both the linear portion and the further portion of the engagement edge). This arrangement allows the device to be used to correctly align the guiding edge of a jig in two dimensions, relative to a reference line or mark that has a shape that conforms to the shape of the guiding edge. The portion of the alignment indicator in the first section can be aligned with a first, linear portion of a reference line, and the portion of the alignment indicator in the second section can be aligned with either a second linear portion of a reference line that is arranged at an angle relative to the first linear portion of the reference line (said angle corresponding to the angle between the first and second linear portions of the guiding edge), or to a curved portion of the reference line, or both. This ensures that the guiding edge is positioned correctly relative to the reference line in two dimensions.

[0021] In this context, it will be appreciated that the expression 'conforms to' does not necessarily mean that said shapes of the reference line and the guiding edge are exactly equal in form and dimensions. Rather, it is to be understood that the reference line conforming to the shape of the guiding edge means that the guiding edge can be positioned relative to the reference line, such that the guiding edge is spaced from the reference line by a predetermined distance. For example, where the reference line comprises a curved portion having a particular length (i.e. the length of an arc forming the curved portion of the reference line), the guiding edge will comprise a curved portion that has a length (i.e. an arc length forming the curved portion of the guiding edge) that different to the length of the curved portion of the reference line, such that a spacing between the guiding edge and the reference line remains constant around the respective curved portions thereof.

[0022] Importantly, the mode of alignment described above allows the jig to be accurately aligned with a reference line, regardless of the angle of that reference line relative to the edges of the worktop. The reference line can be derived by any appropriate means, but in particular may be derived by positioning the two workpieces at the desired angle relative to each other, and using an edge of a pre-cut female recess as a template to mark the reference line on the male workpiece. The device of the present invention can then be used to position the jig by simply aligning the alignment indicator with the reference mark, which sets the jig at the correct angle relative to the workpiece to be cut.

[0023] Preferably, in the first section, the alignment indicator defines a linear portion that is parallel to the linear portion of the engagement edge and spaced from the linear portion of the engagement edge by the predetermined distance, and in the second section, the alignment indicator defines a further portion that is not parallel with the linear portion of the alignment indicator, wherein the further portion of the alignment indicator is spaced from the further portion of the engagement edge by the predetermined distance. This arrangement allows for a reliable and accurate alignment of a guiding edge of a jig relative to a correspondingly shaped reference line.

[0024] The further portion of the alignment indicator may comprise a curved portion that extends away from the linear portion of the alignment indicator. The curved portion can be aligned directly to a corresponding curved portion of a reference line, to allow a jig to be positioned correctly in two dimensions, as described above.

[0025] In embodiments, the linear portion of the engagement edge is a first linear portion of the engagement edge, the engagement edge comprising a second linear portion that is arranged at an angle relative to the first linear portion of the engagement edge, the linear portion of the alignment indicator is a first linear portion, the further portion of the alignment indicator comprises a second linear portion that, in use, is parallel to the second linear portion of the engagement edge and spaced from the second linear portion of the engagement edge, by a constant distance that is equal to the predetermined distance, in a direction perpendicular to the second linear portion of the engagement edge. This arrangement further improves the accuracy of the alignment of a jig with a reference line and, in particular, allows alignment of a guide channel of a jig in two dimensions, by aligning the first linear portion of the alignment indicator with a first linear portion of a reference line, and the second linear portion of the alignment indicator with a second linear portion of a reference line.

[0026] Preferably, the angle between the first and second linear portions of the engagement edge is in the range 90 to 180 degrees. The angle is preferably greater than 90 degrees and less than 180 degrees, more preferably in the range 110 degrees and to 160 degrees, and most preferably in the range 120 degrees and to 150 degrees. In particularly preferred embodiments, the angle is approximately 135 degrees. This provides a suitable angle for forming a mason's mitre joint.

[0027] Preferably, the angle between the first and second linear portions of the alignment indicator is in the range 180 to 270 degrees. The angle is preferably greater than 180 degrees and less than 270 degrees, more preferably in the range 200 degrees to 250 degrees, and most preferably in the range 210 degrees to 240 degrees. In particularly preferred embodiments, the angle is approximately 225 degrees.

[0028] Preferably, one or both of the engagement edge and the alignment indicator is continuous (uninterrupted) between the first section and the second section of the device. Where the engagement edge is continuous between the first section and the second section of the device, this provides a continuous edge which can be engaged with a guiding edge of a guide channel to secure the device against the guiding edge. Where the alignment indicator is continuous between the first section and the second section of the device, this provides a continuous edge for accurately aligning the jig relative to a reference line.

[0029] In some embodiments, both the engagement edge and the alignment indicator are continuous between the first section and the second section, and the predetermined distance between the engagement edge and the alignment indicator is constant between the first section and the second section. This ensures accurate alignment at all positions around an angled part of a reference line.

[0030] Preferably, at least one of the engagement edge and the alignment indicator is curved between the first section and the second section. Generally, a guiding edge of a guide channel of a jig that is used for forming a male or female part of a mason's mitre joint will be curved to allow a smooth transition of a guiding tool along the guide channel between the first and second straight sections of the guiding channel. Where the engagement edge is curved between the first section and the second section of the device, this provides a continuous, curved edge which can be engaged with a curved guiding edge of a guide channel to secure the device against the guiding edge. Where the alignment indicator is curved between the first section and the second section of the device, this provides a continuous, curved edge for accurately aligning the jig relative to a reference line having adjacent linear parts arranged at an angle to each other by means of a curved part of the reference line.

[0031] The engagement edge may define a concave curve between the first section and the second section. This allows the engagement edge to engage with a curved part of a guide channel that is used for forming a male protrusion part of a mason's mitre joint, which is generally convex. Preferably, the alignment indicator defines a convex curve between the first section and the second section. This allows the alignment indicator to match the curve of a guide channel that is used for forming a male protrusion part of a mason's mitre joint, which is generally convex.

[0032] In some embodiments, the engagement edge is a first engagement edge arranged to engage with a first guiding edge of a jig, the device further comprising a second engagement edge arranged to engage with a second guiding edge of said jig that opposes the first guiding edge of said jig, the device comprising at least one cross member extending between the first engagement edge and the second engagement edge to define a spacing between the first engagement edge and the second engagement edge. This arrangement allows the device to be secured in place between the two opposed guiding edges of the guide channel, providing a stable arrangement.

[0033] The device may comprise two cross members extending between the first engagement edge and the second engagement edge to define a spacing between the first engagement edge and the second engagement edge, wherein a first cross member is arranged on a first side of the alignment indicator and a second cross member is arranged on a second side of the alignment indicator. This arrangement prevents flexing of the device on both sides of the angled section and thus ensures that the engagement edge and alignment indicator remain in the appropriate relative positions during use.

[0034] According to a second aspect of the present invention, there is provided an alignment system for aligning a jig with a workpiece to be cut, comprising a first device in accordance with the first aspect, the alignment system further comprising a second device comprising an engagement edge for engaging with a guiding edge of a jig, in use, and an alignment indicator spaced from and the engagement edge by a predetermined distance (and preferably extending parallel to the engagement edge), wherein the predetermined distance between the engagement edge and the alignment indicator of the second device is equal to the predetermined distance between the engagement edge and the alignment indicator of the first device. With this arrangement, the first and second devices can be used in combination to align the jig along the whole length of the guide channel. More specifically, when the second device is positioned within the same guide channel as the first device, with the first engagement edges of the first and second devices being engaged with the same guiding edge of the guide channel, the respective alignment indicators of the first device and the second device are spaced from the guiding edge by the same distance. The first and second Devices can therefore be used in tandem to align different parts or sections of the guide channel with the same reference line, so as to ensure an accurate positioning of the jig. Specifically, the first device will be positioned at a first end of the guide channel (e.g. an end of the guide channel at which first and second straight sections of the guide channel meet) and the second device will be positioned at or towards a second end of the guide channel (e.g. in a straight section of the guide channel). The guide channel can therefore be appropriately positioned at both ends relative to a reference line on the workpiece, ensuring that the jig does not deviate from its intended position.

[0035] Preferably, the second device has a second engagement edge arranged to engage with a second guiding edge of a jig that opposes the first guiding edge of said jig, the second device comprising at least one cross member extending between the first engagement edge and the second engagement edge to define a spacing between the first engagement edge and the second engagement edge. In the same manner as described above in relation to the equivalent features of the first device, this allows for suitable location of the second device within the guide channel.

[0036] Preferably, the second device comprises a body portion defining the cross member, and a leg extending from the body portion in a direction of the first and / or second engagement edge, wherein the leg defines the alignment indicator of the second device.

[0037] According to a third aspect of the present invention, there is provided a jig for cutting an edge on a workpiece, the jig comprising a main body having guide channel defining a guiding edge for guiding a cutting tool, in use, the guide channel comprising a straight section defining a linear portion of the guiding edge, the jig further comprising a device arranged to engage with the main body so as to define an alignment indicator that, in use, is spaced from the linear portion of the guiding edge by a predetermined distance in a direction perpendicular to the linear portion of the guiding edge.

[0038] With this arrangement, the alignment indicator of the device can be positioned relative to the guiding edge of the jig so as to provide a reference point that can be aligned with a reference line marked on a workpiece, so as to offset the guiding edge of the workpiece by the predetermined distance. Accordingly, the advantages of the jig in accordance with this aspect of the invention correspond to those described above in relation to the first aspect.

[0039] However, it will be appreciated that the device may be engaged with the main body of the jig in any appropriate manner and may or may not comprise an engagement edge arranged to engage with the guiding edge of the guide channel, as described above in relation to the first aspect of the invention. Alternative means for engaging the device with the main body of the jig that allow for the appropriate positioning of the alignment indicator relative to the guiding edge maybe provided. For example, the device may comprise a platform arranged to be secured to the main body of the jig by means of fasteners (e.g. screws or locating pins), and an alignment member integral with or fixed to the platform that defines an alignment indicator that is suitably positioned relative to the guiding edge when the platform is secured to the main body. The main body may alternatively or additionally be provided with notches or recesses arranged to accommodate correspondingly shaped protrusions of the device, so as to locate the device on the main body and to appropriately position the alignment indicator relative to the guiding edge. In any such arrangements, the alignment indicator can be appropriately positioned without the need for the device to comprise an engagement edge as described above in relation to the first aspect of the present invention.

[0040] Preferably, the alignment indicator extends parallel to the guiding edge of the device. This improves the accuracy of the alignment compared to, for example, an alignment indicator in the form of a single point. In particularly preferred embodiments, the alignment indicator is an alignment edge of the device that is parallel to the guiding edge and spaced from the guiding edge by a predetermined distance in a direction perpendicular to the guiding edge. The alignment indicator may alternatively comprise a plurality of alignment points, each spaced from the guiding edge by the predetermined distance, such that alignment of all of the alignment points with a linear reference line marked on the workpiece ensures a parallel alignment of the guiding edge of the device with the linear reference line.

[0041] The guide channel may comprise a second section defining a further portion of the guiding edge that is not parallel with the linear portion of the guiding edge, and the device comprises a first section in which the alignment indicator is spaced from the linear potion of the guiding edge by the predetermined distance, and a second section in which the alignment indicator is spaced from the further portion of the guiding edge by the same predetermined distance. The further portion may be linear, extending along a different axis to the linear portion, or may be curved. In either case, the further portion is not parallel with the linear portion of the guiding edge.

[0042] In some embodiments, in the first section of the device, the alignment indicator defines a linear portion that, in use, is parallel to the linear portion of the guiding edge and spaced from the linear portion of the guiding edge by the predetermined distance, and in the second section of the device, the alignment indicator defines a further portion that is not parallel with the linear portion of the alignment indicator, wherein, in use, the further portion of the alignment indicator is spaced from the further portion of the guiding edge by the predetermined distance.

[0043] Preferably, the further portion of the guiding edge comprises a curved portion that extends away from the linear portion of the guiding edge, and wherein the further portion of the alignment indicator of the device comprises a curved portion that, in use, is spaced from the curved portion of the guiding edge by a constant distance that is equal to the predetermined distance, in a radial direction of the curved portion of the guiding edge.

[0044] In embodiments, the curved portions of the alignment indicator and the guiding edge may each define a convex curve, or the curved portions of the alignment indicator and the guiding edge may each define a concave curve.

[0045] In some embodiments, the linear portion of the guiding edge is a first linear portion of the guiding edge, the second section of the guide channel defines a second linear portion of the guiding edge that is arranged at an angle relative to the first linear portion of the guiding edge, the linear portion of the alignment indicator of the device is a first linear portion, the further portion of the alignment indicator comprises a second linear portion that, in use, is parallel to the second linear portion of the guiding edge and spaced from the second linear portion of the guiding edge, by a constant distance that is equal to the predetermined distance, in a direction perpendicular to the second linear portion of the guiding edge.

[0046] Preferably, an angle between the first linear portion and the second linear portion of the guiding edge is greater than 180 degrees and less than 270 degrees.

[0047] Preferably, the alignment indicator of the device is spaced from the guiding edge of the guide channel by a predetermined distance. The predetermined distance preferably remains constant between the first straight section and the second straight section of the guide channel. This allows for accurate alignment and positioning of the jig as described above.

[0048] The device of the jig may be a device in accordance with the first aspect, wherein the device is arranged to be received within the guide channel such that the engagement edge of the device engages with the guiding edge of the guide channel. The device may be the first device of an alignment system in accordance with the second aspect, and the second device of the alignment system may be arranged to be received within the first straight section of the guide channel. The engagement edge of the first device and the engagement edge of the second device may be arranged, in use, to engage with the same guiding edge of the guide channel.

[0049] It will be appreciated that a number of the above features of the jig in accordance with the third aspect of the present invention have the same advantages as outlined previously in relation to the corresponding features of the first aspect of the invention, without being limited to the provision of an engagement edge on the device.

[0050] In particularly preferred embodiments of the jig in accordance with the third aspect of the present invention, the guiding edge of the guide channel comprises a first linear portion and a second linear portion arranged at an angle relative to the first linear portion, and a curved portion extending between the first linear portion and the second linear portion, and wherein: a) the alignment indicator of the device comprises a curved portion that, in use, is spaced from the curved portion of the guiding edge by a constant distance that is equal to the predetermined distance, in a radial direction of the curved portion of the guiding edge; and / or b) the linear portion of the alignment indicator of the device is a first linear portion, the alignment indicator comprising a second linear portion that, in use, is parallel to the second linear portion of the guiding edge and spaced from the second linear portion of the guiding edge, by a constant distance that is equal to the predetermined distance, in a direction perpendicular to the second linear portion of the guiding edge.

[0051] In accordance with a fourth aspect of the present invention, there is provided a method of cutting an edge in a workpiece, the method comprising: a) deriving a line of cut on the workpiece; b) providing a jig according to the third aspect; c) engaging the device with the main body of the jig; d) aligning the alignment indicator of the device with the line of cut marked on the workpiece so as to position the jig on the workpiece; e) rearranging the device so as to be clear of the workpiece to be cut; and f) cutting the workpiece by passing a cutting tool along the guide channel, the cutting tool being guided by a guiding edge of the guide channel.

[0052] The method of the present invention allows for an accurate alignment of the jig with a reference line drawn on a workpiece to be cut, regardless of the angle or orientation of the reference line relative to the edges of the workpiece.

[0053] The line of cut may comprise a linear portion and a further portion that is not parallel with the linear portion, the method comprising aligning a portion of the alignment indicator in the first section of the device with the linear portion of the line of cut, and aligning a portion of the alignment indicator in the second section of the device with the further portion of the line of cut. This allows for alignment of the jig in two dimensions and thus ensures an accurate positioning of the jig.

[0054] Preferably, the alignment indicator of the device comprises a curved portion; the further portion of the line of cut comprises a curved portion extending from the linear portion of the line of cut; and the method comprises aligning the curved portion of the alignment indicator with the curved portion of the line of cut.

[0055] As described above, this allows for use of the device of the present invention for forming a standard mason's mitre joint, wherein the line of cut to be formed has a curved portion. Aligning with a curved portion of a line of cut allows for easy and accurate positioning of the jig in two dimensions.

[0056] Preferably, the guiding edge is a first guiding edge of the guide channel, the guide channel further comprising a second guiding edge that opposes the first guiding edge; the method comprises forming a female recess in a first workpiece using the second guiding edge of the guide channel; deriving the line of cut comprises using the female recess as a template to mark the line of cut on a second workpiece to be joined to the first workpiece; and the method comprises aligning the alignment indicator of the device with the line of cut marked on the second workpiece using the female recess as a template.

[0057] Accordingly, the line of cut can be derived directly from the cooperating female workpiece with which the workpiece to be cut is to be joined, the device of the present invention allowing the jig to be aligned directly with said line of cut by means of the alignment indicator, without the need to derive a secondary reference line spaced from the lines of cut. The second guiding edge may extend parallel to the first guiding edge, such that a spacing between the first guiding edge and the second guiding edge is constant along substantially the entire length of the guide channel, including in any angled or curved portions of the guide channel.

[0058] The device of the method may be the first device of an alignment system according to the second aspect of the invention, the method further comprising placing the second device of the alignment system in the guide channel and aligning the alignment indicator of the second device with the line of cut.

[0059] Non-limiting embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which: Figure 1 is a plan view of a device in accordance with the present invention; Figure 2 is a perspective view of the device of Figure 1; Figure 3 is an enlarged view of detail A shown in Figure 1; Figure 4 is a plan view of a second device of an alignment system in accordance with the present invention; Figure 5 is a perspective view of the second device of Figure 4; Figure 6 is a plan view of a jig in accordance with the present invention; Figure 7 is a plan view of a female workpiece having a recess formed therein; Figure 8 is a plan view showing a male workpiece placed on top of the female workpiece of Figure 7; Figure 9 is a perspective view of an underside of the male and female workpieces arranged as shown in Figure 8; Figure 10 is a plan view of an underside of the male workpiece of Figure 8, wherein a reference line is marked to derive a line of cut; Figure 11 is a plan view of a jig overlaying the underside of the male workpiece of Figures 8 and 10; and Figure 12 is a plan view of the underside of the workpiece of Figures 8, 10 and 11, after a cut has been formed along the reference line.

[0060] With reference to Figures 1 and 2, there is shown a device 1 for aligning a jig 1 with a workpiece to be cut.

[0061] The device 1 comprises a first engagement edge 2 for engaging with a guiding edge of a jig, and a second engagement edge 4 arranged to engage with a second guiding edge of the same jig that opposes the first guiding edge, as will be described in greater detail below. The device 1 further comprises an alignment edge 6 that is parallel to the first engagement edge 2 and spaced from the first engagement edge 2 by a predetermined distance D1. As will be understood from the following description, the alignment edge 6 is an alignment indicator that allows alignment and positioning of the jig relative to a reference mark on a workpiece to be cut. However, it will be appreciated that alternative embodiments of the invention may comprise alternative alignment indicators functioning in substantially the same manner as the alignment edge 6 described below.

[0062] The device 1 comprises a first section 1a in which the alignment edge 6 is parallel to the first engagement edge 2 and spaced from the first engagement edge 2 by the predetermined distance D1, and a second section 1b in which the alignment edge 6 is also parallel to the first engagement edge 2 and spaced from the first engagement edge 2 by the same predetermined distance D1.

[0063] The device 1 comprises an angled section 1c between the first section 1a and the second section 1b. A first linear portion 2a of the first engagement edge 2 in the first section 1a of the device 1 is arranged at an angle relative to a second linear portion 2b of the engagement edge 2 in the second section 1b of the device 1. Accordingly, the first engagement edge 2 is angled, as shown in Figures 1 and 2. An angle α between the first linear portion 2a of the first engagement edge 2 and the second linear portion 2b of the first engagement edge 2 in the second section 1b is the range 90 to 180 degrees and in the illustrated embodiment is approximately 135 degrees, as is preferred.

[0064] In the same way, the alignment edge 6 of the device 1 has a first linear portion 6a in the first section 1a of the device 1 that is arranged at an angle relative to a second linear portion 6b of the alignment edge 6 in the second section 1b of the device 1. The reflex angle β between the first linear portion 6a of the alignment edge 6 and the second linear portion 6b of the alignment edge 6 (see Figure 3) is related to the angle α between the first linear portion 2a of the engagement edge 2 first section 1a and the second linear portion 2b of the engagement edge 2 by the equation (β = 360 - α). Accordingly, the alignment edge 6 runs parallel to the first engagement edge 2 in both the first section 1a and second section 1b of the device 1.

[0065] It will be appreciated from the above description that the angled section 1c of the device 1 is a section extending between the linear portions 2a, 2b of the first engagement edge 2 in the first and second sections 1a, 1b of the device 1, respectively. In the angled section 1c of the device 1, the first engagement edge 2 and the alignment edge 6 may take a number or forms, but both are preferably curved, as described below.

[0066] The first engagement edge 2 provides an edge that can be engaged with an angled section of a guide channel of a jig so as to locate the device within the guide channel of the jig. The alignment edge 6 provides an alignment indicator that is spaced from the first engagement edge 2 of the device by a predetermined distance D1 on both sides on the angled section. In use, the alignment indicator 6 is therefore also spaced from a guiding edge of a guide channel of a jig, with which the engagement edge 2 is engaged, by a predetermined distance. This allows alignment of the jig with a reference line drawn on a workpiece to be cut, the reference line being suitable for forming a male part of the mason's mitre joint, as will be described in greater detail below.

[0067] As shown in the Figures, the first engagement edge 2 and the alignment edge 6 of the device are both continuous between the first section 1a and the second section 1b of the device 1. That is to say, each of the first engagement edge 2 and the alignment edge 6 run continuously (uninterrupted) through the angled section 1c of the device 1, as is preferred. However, it will be appreciated that the device 1 may contain features that interrupt the alignment edge 6 in the angled section, such as a cross member extending from the alignment edge 6 towards the second engagement edge 4, for example. Even where such features are present, it may still be possible to align the uninterrupted portions of the alignment edge 6 (i.e. the linear portions of the alignment edge) with suitable portions of a reference mark to allow positioning of a jig. However, it is preferred that the alignment edge 6 runs continuously (uninterrupted) from the first section 1a to the second section 1b, through the angled section 1c, to allow the continuous angled portion of alignment edge 6 to be used for aligning a jig more accurately and reliably with a reference line on a workpiece.

[0068] Both the first engagement edge 2 and alignment edge 6 are curved between the first section 1a and the second section 1b. That is to say, in the angled section 1c of the device 1, both the first engagement edge 2 and the alignment edge 6 are curved. In such embodiments, the angled section 1c of the device can be defined as the portion in which the first engagement edge 2 and / or the alignment edge 6 are curved.

[0069] The alignment edge 6 therefore comprises a curved portion 6c that is not parallel with the first linear portion 6a and that extends away from the first linear portion 6a. The curved portion 6c joins the first linear portion 6a and the second linear portion 6b. Similarly, the first engagement edge 2 comprises a curved portion 2c that is not parallel with the first linear portion 2a and that extends away from the first linear portion 2a.

[0070] As shown most clearly in Figure 3, a curve of the first engagement edge 2 has a first radius R1 and a curve of the alignment edge 6 has a second radius R2. The curve of the first engagement edge 2 and the curve of the alignment edge 6 have the same centre of curvature C. A difference between the first radius R1 and the second radius R2 is equal to the predetermined distance D1 between the first engagement edge 2 and the alignment edge 6 in the first and second sections 1a, 1b of the device 1. Put mathematically: D1 = R2 - R1. Accordingly, throughout the angled section 1c, the predetermined distance D1 between the first engagement edge 2 and the alignment edge 6 remains constant from the first section 1a to the second section 1b. This is illustrated in Figure 3 at various positions in the angled section 1c.

[0071] As will be appreciated from the discussion below, in the illustrated embodiment, the curve of the first engagement edge 2 is arranged to match (or conform to) a curved guiding edge of a guide channel of a jig with which the device is to be used. Therefore, by engaging the first engagement edge 2 with said curved edge of the guide channel, the device 1 can be located relative to the guide channel. This includes engaging the first and second linear portions 2a, 2b with corresponding linear portions of the guiding edge, as will be described in further detail below. With the arrangement described above, the alignment edge 6 remains at a constant, predetermined distance from the guiding edge of the guide channel and can therefore be used to align the guide channel with a suitable reference line and thus offset the guiding edge of the guide channel from said mark by an appropriate distance. The full utility of this arrangement will be more clearly understood from the following description.

[0072] The first engagement edge 2 defines a concave curve and the alignment edge 6 defines a convex curve. As can be seen from Figure 1, the second engagement edge 4 also defines a convex curve.

[0073] A predetermined distance D2 between the first engagement edge 2 and the second engagement edge 4 is from the same in the first section 1a and the second section 1b. In the illustrated embodiment, the predetermined distance D2 is constant through the angled section 1c of the device 1. A predetermined distance D3 between the second engagement edge 4 and the alignment edge 6 is also constant from the first section 1a to the second section 1b, and through the angled section 1c.

[0074] Whilst in the illustrated embodiment, as described above, the predetermined distance D1 between the first engagement edge 2 and the alignment edge 6 is constant throughout the angled section 1c, it will be appreciated that this may not be the case in all embodiments. For example, the engagement edge 2 may comprise a notch in the angled section 1c of the device 1, which may be required in view of manufacturing constraints, for example.

[0075] It will also be appreciated that embodiments of the present invention may comprise a single engagement edge arranged to engage with one of the opposing edges of the guide channel of a jig. Said engagement edge may be equivalent to either the first engagement edge or the second engagement edge of the embodiment shown in the figures. That is, in one embodiment, the device may comprise an engagement edge defining a concave curve and an alignment edge defining a convex curve or a concave curve. In another embodiment, the device may comprise an engagement edge defining a convex curve and an alignment edge defining a concave curve or a convex curve.

[0076] Returning now to Figures 1 and 2, the device 1 comprises cross members 8 that extend between the first engagement edge 2 and the second engagement edge 4 to define a spacing between the first engagement edge 2 and the second engagement edge 4. The illustrated device comprises two cross members 8, a first cross member 8a being arranged on a first side of the angled section 1c and a second cross member 8b arranged on a second side of the angled section 1c. This arrangement ensures rigidity of the device 1 on both sides of the angled section 1c, such that undesired flexing of the device 1 is prevented, in turn preventing accidental misalignment of the jig.

[0077] With the arrangement described above, the device 1 comprises an opening 10 defined, in part, by the alignment edge 6 and opposing edges 12a, 12b of the first and second cross members 8a, 8b. An edge 14 of the opening 10 opposing the alignment edge 6 is formed in an undulating manner, which in the illustrated embodiment takes the form of a ribbed edge 14. This ensures that the user uses the correct edge (that is, the alignment edge 6) to align the jig with a suitable reference line. In other words, the user is deterred from using the wrong edge (ribbed edge 14) for aligning the jig due to the undulating form. Ease of use of the device in combination with the jig is thereby improved. It will be appreciated that the ribbed arrangement shown in the Figures is exemplary only, and alternative arrangement are possible. As is preferred, a distance between the alignment edge 6 and the opposing edge 14 of the opening 10 is not constant from the first section 1a of the device to the second section 1b of the device, and through the angled section 1c. This provides an undulating arrangement.

[0078] The device 1 further comprises a leg 18 extending from a body portion 16 that defines one of the cross members 8a. The leg 18 defines a further portion of the alignment edge 6 that is spaced from the first engagement edge 2 by the same predetermined distance D1 as the other portions of the alignment edge 6. This additional portion of the alignment edge 6 can be further used to ensure an accurate alignment of a jig relative to a reference line drawn on a workpiece to be cut.

[0079] Referring now to Figures 4 and 5, there is shown a second device 101 (referred to hereafter as "the second device") that may be used alone, or in combination with the device 1 described above with reference to Figures 1 to 3 (referred to hereafter as "the first device") to form an alignment system for aligning a jig with a workpiece to be cut.

[0080] The second device 101 comprises a first engagement edge 102 for engaging with a guiding edge of a jig, and a second engagement edge 104 arranged to engage with a second guiding edge of the same jig that opposes the first guiding edge. The second device 101 further comprises an alignment edge 106 that is parallel to the first engagement edge 102 and spaced from the first engagement edge 102 by a predetermined distance D1. The alignment edge 106 provides an alignment indicator spaced from the first engagement edge 102 for positioning a jig relative to a reference mark on a workpiece, as will be understood from the following description.

[0081] The predetermined distance D1 between the first engagement edge 102 and the alignment edge 106 of the second device is equal to the predetermined distance D1 between the first engagement edge 2 and the alignment edge 6 of the first device 1.

[0082] Accordingly, when the second device 101 is positioned within the same guide channel as the first device 1, with the first engagement edges 2, 102 of the first and second devices 1, 101 being engaged with the same guiding edge of the guide channel, the respective alignment edges 6, 106 of the first device 1 and the second device 101 are spaced from the guiding edge by the same distance. The first and second devices can therefore be used in tandem to align different parts or sections of the guide channel with the same reference line, so as to ensure an accurate positioning of the jig.

[0083] The first and second engagement edges 102, 104 of the second device 101 are linear (that is to say the first and second engagement edges 102, 104 extend in a straight line). Accordingly, the second device 101 can be received within a straight section of a guide channel of a jig and can be moved along said guide channel to substantially any desired position within the straight section.

[0084] The second device 101 has a body portion 116 that defines a cross member 108 extending between the first engagement edge 102 and the second engagement edge 104 to define the spacing between the first engagement edge 102 and the second engagement edge 104.

[0085] The second device 101 further comprises a leg 118 extending from the body portion 116 in the direction of the first and second engagement edges 102, 104. The leg 118 defines the alignment edge 106 of the second device 101. However, it will be appreciated that alternative arrangements are possible for defining an alignment edge 106 (or other alignment indicator) that is spaced from the first engagement edge 102 by a predetermined distance, for example an arrangement having an opening similar to that of the first device 1. Numerous alternative arrangements will be conceivable to the skilled person.

[0086] Turning now to Figure 6, there is shown a jig 20 for cutting an edge on a workpiece. The jig 20 comprises a main body 22 having a guide channel 24 for guiding a cutting tool (in particular, a router). The guide channel 24 comprises a first straight section 24a and a second straight section 24b arranged at an angle relative to the first straight section 24a.

[0087] A first guiding edge 26 of the guide channel 24 is arranged for use in forming a male protrusion of a mason's mitre joint and a second guiding edge 28 of the guide channel 24 is arranged for use in forming a female recess of the same mason's mitre joint. As such, the first guiding edge 26 defines a convex curve that is arranged to engage with the first engagement edge 2 of the first device 1, and the second guiding edge 28 of the guide channel 24 defines a concave curve that is arranged to engage with the second engagement edge 4 of the first device 1. In doing so, the first device 1 is located in an angled part of the guide channel 24 (i.e. a part of the guide channel 24 joining the first and second straight sections 24a, 24b) and is appropriately located by means of the angled arrangement of the engagement edges 2, 4 of the first device 1 and the guiding edges 26, 28 of the guide channel 24, so as to substantially prevent movement of the first device 1 within the guide channel 24. The alignment edge 6 of the first device 1, and more particularly the curved portion 6c of the alignment edge 6, is provided in a fixed position relative to the guide channel 24, such that the alignment edge 6 is spaced from the first guiding edge 26 by a predetermined distance.

[0088] The first straight section 24a of the guide channel 24 defines a first linear portion 26a of the guiding edge 26, the second straight section 24b defines a second linear portion 26b of the guiding edge 26. Although not shown, an angle between the first linear portion 26a and the second linear potion 26b of the guiding edge 26 is equal to the angle β between the first linear portion 6a and the second linear portion 6b of the alignment edge 6 (as indicated in Figure 3). A curved portion 26c of the guiding edge 26 extends away from the first linear potion 26a (the curved portion 26c is not parallel with the first linear portion 26a). The curved portion 6c of the alignment edge 6 of the first device 1 is spaced from the curved portion 26c of the guiding edge 26 by a constant distance that is equal to the predetermined distance, in a radial direction of the curved portion 26a of the first guiding edge 26.

[0089] The second linear portion 6b of the alignment edge 6 is parallel to the second linear portion 26b of the guiding edge 26. The spacing between the second linear portion 6b of the alignment edge 6 and the second linear portion 26b of the guiding edge 26 (in a direction perpendicular to the second linear portion 26b of the guiding edge 26) is constant and is equal to the predetermined distance.

[0090] With the above arrangement, the spacing between the alignment edge 6 and the first guiding edge 26 is constant throughout the angled section 1c of the first device 1. Aligning the alignment edge 6 with a reference line marked on a workpiece therefore spaces the guiding edge 26 from said reference line by the predetermined distance.

[0091] It will be appreciated that, in the context of the present invention, each of the second linear portion 6b and the curved portion 6c of the alignment edge 6 is a `further portion' of the alignment edge 6 that is not parallel with the first linear portion 6a of the alignment edge. In the same way, each of the second linear portion 26b and the curved portion 26c of the first guiding edge 26 is a `further portion' of the guiding edge 26 that is not parallel with the first linear portion 26a of the guiding edge 26. Since the respective portions of the alignment edge 6 are spaced from the corresponding portions of the first guiding edge 26 by the same predetermined distance, either or both of the second linear portion 6b and the curved portion 6c of the alignment edge 6 can be used to position the jig relative to a reference mark drawn on a workpiece, in conjunction with the first linear portion 6a. In further embodiments, the `further portion' could comprise both a curved portion extending away from the first linear portion, and a second linear portion adjoining the curved portion, the second linear portion being arranged at an angle relative to the first linear portion.

[0092] The second device 101 is also arranged to be located within the guide channel 24 with the first engagement edge 102 of the second device 101 engaging with the first guiding edge 26 of the guide channel 24, and the second engagement edge 104 of the second device 101 engaging with the second guiding edge 28 of the guide channel 24. The alignment edge 106 of the second device 101 is spaced from the first guiding edge 26 of the guide channel 24 by a predetermined distance, which is the same as the predetermined distance of the alignment edge 6 of the first device 1 from the first guiding edge 26 of the guide channel 24. As will be appreciated from Figure 6, the alignment edges 6, 106 of the first and second Devices 1, 101 define an imaginary line extending along the guide channel 24 that has a constant spacing from the first guiding edge 26 of the guide channel 28, throughout the first and second straight seconds 24a, 24b and in the angled part of the guide channel 24 extending therebetween.

[0093] Use of the jig 20 for forming a male protrusion part of a mason's mitre joint in a workpiece will now be described with reference to Figures 7 to 12.

[0094] Figure 7 illustrates a first workpiece 30 (termed "the female workpiece"), in which a recess 32 has been formed using the second guiding edge 28 of the jig 20 as shown in Figure 6. An edge 34 of the recess 32 has a generally concave portion 34a, corresponding to the concave form of the second guiding edge 28 of the jig 20 (factoring in an offset between the guiding edge 28 and the cutting blade during the cutting operation). The recess 32 forms the female part of a mason's mitre joint for joining the Female Workpiece 30 to a cooperating male workpiece.

[0095] As can be seen in Figure 7, a side edge 30c of the female workpiece 30 is not at right angles to front and back edges 30a, 30b of the workpiece 30. This is for placement of the workpiece 30 in a room in which the walls are not at right angles to each other. In this regard it will be appreciated that the female workpiece 30 is arranged to be positioned in a corner of the room, with the back edge 30b of the female workpiece 30 abutting a first wall and the side edge 30c of the female workpiece 30 abutting a second, adjacent wall, that is not at right angles to the first wall. Accordingly, an angle of the side edge 30c relative to the back edge 30b (and the front edge 30a, which is parallel to the back edge 30b) of the female workpiece 30 corresponds to the angle between two walls of a room in which the workpiece 30 is to be positioned as a worktop.

[0096] Referring now to Figure 8, a second workpiece 36 (termed "the male workpiece") is placed on top of the female workpiece 30 with a back edge 36b of the male workpiece 30 being generally aligned with the side edge 30c of the female workpiece 30. The front edge 36a of the male workpiece 36 is aligned with the point at which the front edge 30a of the female workpiece 30 and the edge 34 of the recess 32 meet (i.e. the point at which the cut forming female recess 32 intersects the front edge 30a of the female workpiece 30).

[0097] In Figure 8, the edge 34 of the female recess 32 underlying the male workpiece 36 is shown in dotted lines. It will be appreciated that the cut to be formed in the male workpiece 36 to form a corresponding protrusion can be derived from the edge 34 of the recess 32 in the female workpiece 30.

[0098] Figure 9 shows a perspective view or the underside of the female workpiece 30 and male workpiece 36 arranged as shown in Figure 8, with the male workpiece 36 being placed on top of the female workpiece 30. The user can mark a reference line 38 on the underside of the male workpiece 36 by scribing along the edge 34 of the recess 32 formed in the Female Workpiece 30. The reference line 38 will thus include a curved portion that matches the concave portion 34a of the edge 34 of the recess 32.

[0099] It will be appreciated that the method described provides one suitable method for deriving a line of cut on the male workpiece 36 in the appropriate position and with the appropriate angle relative to the front edge 36a and back edge 36b of the male workpiece 36, however the line of cut on the male workpiece 36 could be conceivably derived by other methods with careful consideration of the angle of the male workpiece relative to the female workpiece in the installation. Also, whilst the Figures show the reference line 28 being drawn on the underside of the male workpiece 36, it will be appreciated that in other installations, the male workpiece may be placed beneath the female workpiece and the reference line can be drawn on the top surface of the male workpiece.

[0100] Referring now to Figure 10, there is shown the underside of the male workpiece 36, with the line of cut (reference line 38) drawn. The reference line 38 comprises a curved portion 38c, wherein a first linear part 38a of the reference line 38 is arranged at an angle relative to a second linear part 38b of the reference line 38. The curved portion 38c corresponds to the concave part 34a of the edge 34 of the female recess 32 formed in the female workpiece 30. As can be seen from Figure 10, the first linear part 38a of the reference line 38 is not at right angles relative to the front or back edges 36a, 36b of the male workpiece 36, such arrangements being commonly referred to as "out of square".

[0101] Referring now to Figure 11, the jig 20 is placed on the underside of the male workpiece 36 and the first and second devices 1, 101 of the alignment system are placed within the guide channel 24 of the jig 20 in the manner described above. The alignment edges 6, 106 of the first and second devices 1, 101 are aligned with the reference line 38 indicating the line of cut to be formed in the male workpiece 36.

[0102] In particular, the curved portion 6c of the alignment edge 6 of the first device 1 is aligned with a curved portion 38c of the line of cut (the curved portions 6c and 38c are not shown in Figure 11 for clarity, but visible in Figure 6 and 10, respectively). This allows the jig 20 to be accurately positioned relative to the male workpiece 36 in two dimensions. That is, the jig 20 is positioned in a vertical direction and in a horizontal direction (that is, vertical and horizontal as shown in Figure 11), such that the appropriate offset is provided between the guiding edge 26 and the reference line 38 at all positions, which offset will depend on the particular equipment being used. Use of the device 1 also accounts for the angle of the reference line 38 relative to the edges of the workpiece 36.

[0103] At the same time, the alignment edge 106 of the second device 101 can be used to align with a linear part 38a (shown in Figure 10) of the reference line 38 along the first straight section 24a of the guide channel 24, to ensure accurate positioning of the jig 20 along the entire length of the cut.

[0104] This process defines a spacing between the reference line 38 and the first guiding edge 26 of the guide channel 24 of the jig 20, such that when a cut is performed by passing a cutting tool (e.g. a router) along the guide channel 24, the guiding edge 26 is appropriately spaced from the reference line 38 so as to perform the cut along the desired line of cut indicated by the reference line 38. For example, in a routing operation, a distance between the router blade and the first guiding edge 26 of the guide channel 24 may be defined by a guide bush, which is arranged to hold the router and to be received within the guide channel 24, and to position the router blade at a predefined distance from the first guiding edge 26 of the guide channel 24. This predefined distance may vary depending on the particular equipment being used, however typically may be 8.65mm. The appropriate offset between the router blade and the guiding edge may in other embodiments be defined by a bearing guide of the blade or similar component. In any case, it will be appreciated that the present invention allows for the provision of an appropriate offset between the reference line 38 and the guiding edge 26, which can varied according to the particular equipment being used.

[0105] In order to perform the cut, the first and second devices 1, 101 are removed from the guide channel 24. That is, the first and second devices 1, 101 are rearranged so as to the clear of the workpiece 36 to be cut. It is preferred that the first and second devices 1, 101 are removed altogether, however other arrangements in which the first and second Devices 1, 101 are rearranged (such as being moved to a position in which they are clear of a portion of the guide channel 24 that is being used to form the cut), would be possible.

[0106] Once the first and second Devices 1, 101 have been appropriately rearranged, a cut is performed by guiding a cutting tool (e.g. a router) along the first guiding edge 26 of the guide channel 24, so as to form a cut along the desired line of cut indicated by the reference line 38. It will be appreciated that the first and second devices 1, 101 will have a predetermined distance between the engagement edges 2, 4, 102, 104 and alignment edges 6, 106 thereof that it suitable for a particular combination of jig and guide bush / router.

[0107] Figure 12 illustrates the male workpiece 36 after the cut has been formed. The cut is accurately angled relative to the front and back edges 36a, 36b of the male workpiece 36, such that the protrusion formed in the male workpiece 36 can be accommodated within the recess 32 of the female workpiece 30 (as shown in Figure 7), without misalignment of the joining edges of the male and female workpieces.

[0108] As will be appreciated from the above description, the device, alignment system, jig and method of the present invention allow accurate positioning of a jig relative to a line of cut that can be derived directly from a corresponding workpiece (a female workpiece), without the user needing to accurately derive a secondary reference line that is appropriately spaced to account for the offset between the router blade and the guiding edge of the guide channel which is to be used for forming the cut.

[0109] The invention has been described above with reference to specific embodiments, given by way of example only. It will be appreciated that different arrangements of the system are possible, which fall within the scope of the appended claims.

Claims

1. A jig for cutting an edge on a workpiece, the jig comprising a main body having guide channel defining a guiding edge for guiding a cutting tool, in use, the guide channel comprising a straight section defining a linear portion of the guiding edge, the jig further comprising a device arranged to engage with the main body so as to define an alignment indicator that, in use, is spaced from the linear portion of the guiding edge by a predetermined distance in a direction perpendicular to the linear portion of the guiding edge.

2. A jig as claimed in claim 1, wherein the alignment indicator extends parallel to the guiding edge.

3. A jig as claimed in claim 2, wherein the alignment indicator comprises an alignment edge that is parallel to the engagement edge and spaced from the engagement edge by a predetermined distance.

4. A jig as claimed in any one of claims 1 to 3, wherein the guide channel comprises a second section defining a further portion of the guiding edge that is not parallel with the linear portion of the guiding edge, and wherein the device comprises a first section in which the alignment indicator is spaced from the linear potion of the guiding edge by the predetermined distance, and a second section in which the alignment indicator is spaced from the further portion of the guiding edge by the same predetermined distance.

5. A jig as claimed in claim 4, wherein, in the first section of the device, the alignment indicator defines a linear portion that, in use, is parallel to the linear portion of the guiding edge and spaced from the linear portion of the guiding edge by the predetermined distance, and in the second section of the device, the alignment indicator defines a further portion that is not parallel with the linear portion of the alignment indicator, wherein, in use, the further portion of the alignment indicator is spaced from the further portion of the guiding edge by the predetermined distance.

6. A jig as claimed in claim 5, wherein the further portion of the guiding edge comprises a curved portion that extends away from the linear portion of the guiding edge, and wherein the further portion of the alignment indicator of the device comprises a curved portion that, in use, is spaced from the curved portion of the guiding edge by a constant distance that is equal to the predetermined distance, in a radial direction of the curved portion of the guiding edge.

7. A jig as claimed in claim 5 or 6, wherein: the linear portion of the guiding edge is a first linear portion of the guiding edge, the second section of the guide channel defines a second linear portion of the guiding edge that is arranged at an angle relative to the first linear portion of the guiding edge, the linear portion of the alignment indicator of the device is a first linear portion, the further portion of the alignment indicator comprises a second linear portion that, in use, is parallel to the second linear portion of the guiding edge and spaced from the second linear portion of the guiding edge, by a constant distance that is equal to the predetermined distance, in a direction perpendicular to the second linear portion of the guiding edge.

8. A device suitable for use as the device of a jig as claimed in any one of claims 1 to 7 for aligning said jig with a workpiece to be cut, the device comprising an engagement edge suitable for engaging with a guiding edge of a jig, in use, and an alignment indicator spaced from the engagement edge by a predetermined distance.

9. An alignment system for aligning a jig with a workpiece to be cut, the alignment system being suitable for use with a jig as claimed in any one of claims 1 to 7, the alignment system comprising a first device as claimed in claim 8, the alignment system further comprising a second device comprising an engagement edge for engaging with a guiding edge of a jig, in use, and an alignment indicator spaced from the engagement edge by a predetermined distance, wherein the predetermined distance between the engagement edge and the alignment indicator of the second device is equal to the predetermined distance between the engagement edge and the alignment indicator of the first device.

10. A jig as claimed in any one of claims 1 to 7, wherein the device is a device as claimed in claim 8, and wherein the device is arranged to be received within the guide channel such that the engagement edge engages with the guiding edge of the guide channel.

11. A jig as claimed in any one of claims 1 to 7 or 10, wherein the device is the first device of an alignment system as claimed in claim 9, and wherein the second device of the alignment system is arranged to be received within the straight section of the guide channel.

12. A method of cutting an edge in a workpiece, the method comprising: a) deriving a line of cut on the workpiece; b) providing a jig as claimed in any one of claims 1 to 7, 10 or 11; c) engaging the device with the main body of the jig; d) aligning the alignment indicator of the device with the line of cut marked on the workpiece so as to position the jig on the workpiece; e) rearranging the device so as to be clear of the workpiece to be cut; and f) cutting the workpiece by passing a cutting tool along the guide channel, the cutting tool being guided by the guiding edge of the guide channel.

13. A method as claimed in claim 12, wherein: the line of cut comprises a linear portion and a further portion that is not parallel with the linear portion, the jig is a jig as claimed in any one of claims 4 to 7, the method comprising aligning a portion of the alignment indicator in the first section of the device with the linear portion of the line of cut, and aligning a portion of the alignment indicator in the second section of the device with the further portion of the line of cut.

14. A method as claimed in claim 13, wherein: the alignment indicator of the device comprises a curved portion; the further portion of the line of cut comprises a curved portion extending from the linear portion of the line of cut; and the method comprises aligning the curved portion of the alignment indicator with the curved portion of the line of cut.

15. A method as claimed in claim 13 or 14, wherein: the guiding edge is a first guiding edge of the guide channel, the guide channel further comprising a second guiding edge that opposes the first guiding edge; the method comprises forming a female recess in a first workpiece using the second guiding edge of the guide channel; deriving the line of cut comprises using the female recess as a template to mark the line of cut on a second workpiece to be joined to the first workpiece; and the method comprises aligning the alignment indicator of the device with the line of cut marked on the second workpiece using the female recess as a template.

Images