Board cutter for cutting vertical or horizontal positioned boards

Abstract

A portable board cutting system used to cut in both the vertical and horizontal position. A leaned vertical stack of boards can be worked upon one at a time cutting long rips. A pair of members each with a sliding measuring scale, adjustable guide supports and stops are slotted behind, but not fully, the front board, a middle member is also placed behind to ensure board flatness. A track is then rested on the supports for a saw. Repeat cuts are possible. As the board is cut it is securely held against members by cramps. Multiple 20mm holes in members along with dowels / dogs are used to position boards and for mft compatibility. Once boards are ripped to width the members can be placed horizontally on trestles or mft top for crosscutting of rips.

Description

[0001] Board cutter for cutting vertical or horizontal positioned boards

[0002] This invention relates to a portable device to cut or router sheet material in the vertical and horizontal position.

[0003] Board materials such as plywood, medium-density fibreboard (MDF), chipboard, melamine, plasterboard or insulation boards etc. are generally available in 8-foot x 4-foot (2440 mm x 1220 mm) sheets. Sometimes even larger sheets may be used. These sheets can be quite heavy (a standard 8 x 4, 18 mm thick moistureresistant MDF (MRMDF) board weighs 36 kg) and due to their size can be particularly cumbersome. The normal practice of cutting these boards (excluding plasterboard) to production sizes in a small professional or home workshop, a DIY setting or indeed on a construction site is to lay the board horizontally on trestles with adequate supports so that as the cutting proceeds, pieces stay supported. As pieces are cut, they are removed and often the board on the trestles needs repositioning over the supports so that another cut can be made in a safe manner. This takes up quite a bit of floor area as access around the board is required, the process also needs two men and as each board must be individually measured and cut, diligence must be kept to prevent errors in measuring. Because of the nature of certain board materials and when working with thin sheets, binding of the cutting blade can be a real issue and unless great care is taken often a cut piece can unexpectedly drop or even fall onto the floor because of inadequate support risking material damage or personal injury. Sometimes the person assisting but not operating the saw may be required to support the offcut of material this can put his hands into the danger zone near the blade or worse still a single worker may try and support the offcut and operate the saw simultaneously. Another issue can be the cable or / and dust extraction hose gets snagged upon the edge of the board or the trestle or supports as it is pulled along with the saw along long cuts. This can result in a sudden pull back of the saw resulting in potential material and personal damage. There is therefore a need to provide an improved means by which to support and aid the cutting of such board materials.

[0004] It is therefore an aim of the present invention to provide a cutting aid apparatus which overcomes the aforementioned problems associated with the prior art.

[0005] It is a further aim of the present invention to provide a method of using an improved cutting aid apparatus which overcomes the aforementioned problems associated with the prior art.

[0006] In a first aspect of the present invention there is provided a cutting aid apparatus, said cutting aid apparatus including: first and at least second elongate members, arranged parallel to and spaced apart from one another; one or more movable guide support members provided on each of the first and second elongate members; said guide support members being movable along a length of the first and second elongate members; and a guide rail member arranged to rest on and / or abut first guide support members provided on the first and second elongate members, characterized in that at least one clamping member is provided on each of the first and second elongate members, arranged to clamp and retain a cut portion of material, in use.

[0007] Typically, said first and second elongate members are arranged to be positioned substantially vertically in use, and said guide rail member is arranged to rest on top of first, upper guide support members in use. Further typically, a board or panel of material to be cut is arranged, in use, to be supported by the apparatus of the present invention in an orientation such that the plane of said material is vertical and parallel with the first and second elongate members.

[0008] Preferably, the guide rail member locates, in use, between the movable guide support member and clamping member.

[0009] Typically, said guide support members are also arranged, in use, to support and retain in position a board or panel of material to be cut.

[0010] In some embodiments, at least first, upper and second, lower guide support members are provided on each of the first and second elongate members. Typically, the first, upper guide support members are arranged to support the guide rail member, in use.

[0011] Preferably, each of said first and second elongate members are arranged to retain and support a side edge or end of a board or panel of material to be cut, in use.

[0012] In one embodiment, said guide support members comprise a body portion, attached to the respective elongate member; and a retaining portion, which extends from the body portion such that a space or gap is provided between the elongate member and retaining portion. Typically, a side edge or end of a board or panel of material to be cut is arranged to be located in said gap or space, supporting and retaining the same, in use.

[0013] Typically, said guide rail member is arranged to locate on the retaining portion of the guide support members, in use. In some embodiments, one or more tracks are provided on the first and second elongate members, extending along a length of a front face thereof. Typically, said guide support members engage in slidable movement along at least one of said one or more tracks.

[0014] In some embodiments, said first and second elongate members include a measuring scale provided thereon. Typically, said measuring scales are movable along said elongate members, as required by a user.

[0015] In some embodiments, the first and second elongate members each include detachably attachable foot portions. Typically, said foot portions are removable and reversible. Thus, typically, in a first arrangement, said foot portions may be attached to the elongate members to enable the same to stand substantially vertically, in use; and in a second arrangement said foot portions may be reversed and attached to the elongate members causing the same to stand at an angle relative to the vertical, tilted towards one another, in use. Preferably, said second arrangement provides additional support for a board or panel of material being cut when in a vertical position, in use.

[0016] In some embodiments, each of said first and second elongate members includes a first plurality of apertures formed in a front face and along a length thereof. Typically, said apertures enable, with the provision of one or more dowel or dog members, the location, support and cutting of smaller-sized boards or panels of materials, in use.

[0017] In one embodiment, said at least one clamping member on each of said first and second elongate members is located in and movable along one or more tracks provided to extend along a length of a front face of the elongate members, and arranged to be secured in position as required by a user.

[0018] In another embodiment, a plurality of slots or channels is provided in and along a length of a side edge or face of each of the elongate members. Typically, said clamping member is locatable in and removable from a desired slot or channel as required by a user. Further typically, said side edge or face of the elongate member in which said slots or channels are formed, is one facing or opposing the corresponding side or face of the other elongate member, otherwise defined as the “inward” side or face.

[0019] In some embodiments, said first and second elongate members include removable and replaceable front faces. The front faces of the elongate members, against which the board or panel of material to be cut rests, are exposed to the protruding cutting blade and so over time may be cut and wear. As such, by providing removable front faces, this enables the same to be replaced as and when required by a user.

[0020] In some embodiments, the first and second elongate members further include a back-stop member provided on a rear face thereof. Typically, said back-stop member is arranged to provide support and ensures tight and vertical positioning of the elongate members against a support surface, in use.

[0021] In some embodiments, a second plurality of apertures is provided formed in a front face and along a length thereof.

[0022] In some embodiments of the present invention, a third elongate member is provided, locatable in use intermediate, parallel to and in the same plane as the first and second elongate members. Typically, said third elongate member provides additional support to the first and second elongate members for material to be cut, in use.

[0023] Preferably, said third elongate member includes at least one clamping member thereon.

[0024] Preferably, said third elongate member includes a plurality of apertures formed in a front face and along a length thereof.

[0025] Preferably, said third elongate member includes one or more tracks provided extending along a length of a front face thereof.

[0026] Preferably, said third elongate member includes a plurality of slots or channels provided in and along a length of a side edge or face thereof.

[0027] Preferably, said third elongate member includes a removable and replaceable front face.

[0028] Preferably, said third elongate member includes a back-stop member provided on a rear face thereof.

[0029] According to a further aspect of the present invention, there is provided a method of using a cutting aid apparatus as defined above, said method including the steps of: placing the first and second elongate members in a vertical orientation, spaced apart from one another and abutting a support surface; locating a board or panel of material to be cut between the first and second elongate members and retaining the same in position via the provision and securing of one or more guide support members on each elongate member; adjusting a first, upper guide support member on each of the first and second elongate members to a desired vertical position according to a cutting location of the board or panel of material; locating the guide rail member atop the first, upper guide support members, forming a cutting line along the board or panel of material; clamping an upper edge of the board or panel of material to be cut by at least one clamping member provided on each of said first and second elongate members; and cutting along the board or panel of material along a line defined by the guide rail member.

[0030] In some embodiments, a third elongate member is provided and located in a vertical orientation intermediate the first and second elongate members.

[0031] To overcome the problems associated with the prior art and discussed above, the present invention allows one man to cut boards whilst they are leaned against a wall, stacked up in the vertical position taking the invention to each sheet one at a time and working through the stack of boards. Comprising two and optionally three sections, a first, left elongate member, a second, right elongate member, and optionally a third, middle elongate member. The elongate members are placed behind the first / front board. The left and right members have a sliding lockable measuring scale each and on the rear removable position stops to abut the board behind, these stops may be built in perhaps using a push spring to activate, or be hinged. The left and right members make a pair and incorporate adjustable guide supports enabling a guide rail for a saw, ideally the type commonly used with track or plunge saws but may be another type of suitable straight edge to be rested. A saw is then run along the guide rail and a cut made. All members can feature sacrificial front pieces which can be replaced as needed. The middle member is mainly as an additional support to ensure board straightness, flimsy or very thin boards may require additional supports. The left and right members also feature repeat stop s enabling multiple boards to be cut to size yet only having measured once.

[0032] All the members feature 20mm apertures or holes at 96mm centres, this configuration is the same as multi-function table (MFT) tops for additional features. The holes allow with the aid of a dowel / dog, support for smaller size boards to be placed upon to aid further cutting. The holes also allow temporary support for the guide rail and clamping members in the form of cramps whilst the adjustable guide supports are moved. Other supports may be used instead such as retractable supports or hinged sections. The members also feature side slots to allow a track style cramp to be inserted enabling the holding of the offcut piece. Other holding devices may be considered such as a gravity clamp. The left and right members also have an additional row of 20mm apertures or holes to facilitate material stop dowels / dogs.

[0033] The present invention is designed to be able to tilt back approx. 10 degrees as to be coplanar with the stacked sheets that should also be at approx. 10 degrees tilt. The feet are removable and are so shaped to slightly tilt the left and right members inwards at the top when viewed from the front towards the middle member, this is to ensure that even on floors that are not perfectly level or flat the left and right members will hold snugly up to the board behind keeping it tight against the back stop s thus ensuring rigidity and trueness. When cutting the last sheet or if only one in number or if present invention is used in a fashion where boards are taken to it rather than main intention then incline to the middle of the left and right member may be undesirable so the removable feet can be reversed to give a standard plumb position. An alternative arrangement may have built in feet that slide in and out of desired positions. The present invention all but eliminates the problem of the lead and / or hose getting caught on trestles as all the long cuts are performed while boards are substantially vertical, and the lead and hose merely drape downwards and drag along floor.

[0034] The present invention negates the need for two men, thus saving on labour. Also, the dramatically reduced floor area now needed saves valuable space particularly in small work areas.

[0035] So far, the present invention has been used in the vertical to rip boards along the length to desired width.

[0036] The present invention can also be used horizontally to cut ripped boards to crosscut size to give finished length by width pieces.

[0037] Placed on trestles with perhaps the addition of supports underneath the members are laid down and should be securely held in a squared and parallel orientation to allow properly squared cuts, or laid down onto a suitably supported MFT top and utilizing the 20mm holes at 96mm centres in the members with suitable dowels / dogs conjoining, ensuring squareness of cuts. Again, repeatable cuts are achieved using the adjustable scale, guide rail supports and repeat stops. As boards have now been ripped into more manageable sizes and weights one man can still comfortably continue unaided and the floor area required is much less than if working on full size boards. The members feet do not have to be removed and can stay on for horizontal operation if deemed acceptable.

[0038] Embodiments of the present invention will now be described with reference to the accompanying figures, wherein: Figure 1 shows a cutting aid apparatus in accordance with an embodiment of the present invention with a board in front and a guide rail resting on adjustable guide supports;

[0039] Figure 2 shows front elevation of a second, right elongate member, in accordance with an embodiment of the present invention;

[0040] Figures 3a-b show front and side elevations of a first, left elongate member, in accordance with an embodiment of the present invention;

[0041] Figures 4a-b show pictorial views of first, left and third, middle elongate members, in accordance with an embodiment of the present invention;

[0042] Figure 5 shows a horizontal pictorial view of a cutting aid apparatus according to an embodiment of the present invention enabling cross cutting of ripped boards; and

[0043] Figure 6 shows an alternative cramping option, in accordance with an embodiment of the present invention.

[0044] In figure 1 the first, left elongate member 1 , the second, right elongate member 3, and the optional third, middle elongate member 2 are placed behind the board 15 as it is leaned vertically against a support surface such as a wall. The adjustable guide supports 6 are so placed that when the guide rail 14 is rested upon them a first reference cut / clean edge can be made. This cut may be so minor that the cramps 16 for holding the cut piece may not be needed. Once this first cut is made then desired sizes can be cut whilst being securely held by cramps, on very rough work a first clean edge cut may not be needed in some circumstances. In figure 2, the angled side slots 5 show how a clamping member in the form of a cramp 16 can, when placed within them, slide up or down to give enhanced cramping coverage. The multiple 20mm dowel / dog apertures / holes 4 offer many board height options. The second row of dowel / dog holes 17 can be used as board stops when the present invention is in the horizontal orientation, this helps ensure square cuts. The removable foot 7 is reversible, because of the angle of the foots top this gives two stance options, one true vertical and the other slightly inclined towards the middle member when viewed from the front, this oddly helps keep the member vertical as it pushes removable back stops tight against board behind aiding rigidity. Only the left and right members feature feet that offer inclined stance.

[0045] In figure 3 the adjustable measuring scale 9 allows positional measuring, there may be alternative scales such as shorter and longer ones or different measuring systems to best suit user requirements. The adjustable position stops 11 enable repeat cutting as the adjustable guide supports 6 can be moved for a cut and then moved back abutting the stop 11 ensuring accuracy. The second row of 20mm dowels / dog apertures / holes 17 may not go all the way through the member. The removable back stop 12 ensures the member is held upright tight against the board behind, in practice this helps give the present invention added stability, though being removable, member can lay flat when used in horizontal orientation. The track 8 allows free movement and removal of all adjustable components.

[0046] In figure 4 the middle member 2 is shown having just one row of 20mm dowel / dog holes 4. The angled side slots 5 are also in the middle member for cramping options, though in practice cramping with just the left member 1 and the right member 2 is usually adequate. During use as the saw blade will be set to protrude through board by approx. 1.5mm the front of members will end up with lots of cuts in them, after extensive use this may become undesirable, though highly unlikely to affect performance, sacrificial front sections 18 are fitted to all members and can therefore be replaced as required.

[0047] In figure 5 the left member 1 and the right member 3 are shown laid horizontally upon trestles 13 for the cross cutting of the ripped boards. The middle member 2 may also be used as extra support for the board. The present invention can also be laid upon an MFT top upon trestles and the 20mm dowel / dog holes 4 used to cojoin them accurately and squarely. An MFT top is a precision computer numerical control (CNC) machined board with multiple 20mm holes at 96mm centres.

[0048] In figure 6 a side section of the second, right member 3 is shown with an alternative cramping option. With the use of a track on the inside edge of member a self-adjusting gravity clamp can be slid up or down and fixed at desired location clamping onto board. The clamp securely holds the piece of board being cut and can be disengaged once cut complete to allow board to drop just the approximately 2 mm saw blade thickness onto board piece below.

[0049] Further clauses defining preferred examples of the invention are provided below:

[0050] 1. A portable board dimensioning cutting system which enables cutting or routing of boards whilst they are stood vertically or laid horizontally.

[0051] 2. A portable cutting system according to clause 1 , that allows a leaned vertically stacked pile of boards to be cut to width (or rip size) one board at a time working through the stack where it stands. 3. A portable cutting system according to clause 2 , which works by placing vertical members behind the front sheet but through the use of protruding adjustable supports on tracks on both left and right members a saw guide preferably the type used for a plunge or track saw can be supported, a saw run along the track and a cut can be made.

[0052] 4. A portable cutting system according to clause 3, by using repeat stops on tracks on the left and right members repeat cuts are possible meaning multiple boards can be worked through, all being dimensioned to the same width whilst only having measured once.

[0053] 5. A portable cutting system according to clause 3, through the use of cramps / clamps the piece to be cut or uppermost section of board is securely held in position so that when the cut is made the board does not simply fall, relaxing those cramps allows the board to drop just the approximately 2mm blade thickness upon the piece of board below to allow removal.

[0054] 6. A portable cutting system according to clause 5, the cramps that hold the uppermost section as the board is cut are the track style cramps which slide into angled side slots within the members, as there are many side slots any board cutting position can be cramped the slot angle enables correct positioning of said cramps and the board is held against member and because the cramps slot within the member there is no fouling of the board behind.

[0055] 7. A portable cutting system according to clause 5, the cramp or clamp that holds the uppermost section of board during cutting may be within a track on the members and be of a gravity clamp type, the track allowing full vertical movement and positional clamping. 8. A portable cutting system according to clause 1 , The feet of the members are removable and reversible, removing them for using system in horizontal position and reversible to give two upright positions to left and right member, one offers a slightly inclined inwards stance when viewed from the front to ensure member is held well against the board behind abutting the member back stops, and the other position is a more upright stance when viewed from the front for using the system independently of a stack or for the cutting of the last sheet.

[0056] 9. A portable cutting system according to clause 8, An alternative foot arrangement using built in sliding feet that can be locked at desired angle.

[0057] 10. A cutting system according to clause 1, all members have 20mm holes at 96mm centres running along their length, these are so dowels / dogs can be inserted to offer different board height positions with the board (probably an offcut) being rested thereon, also the 20mm holes can be used to affix the members to an MFT style top to guarantee parallel and square cuts when used horizontally.

[0058] 11. A portable cutting system according to clause 1, when used horizontally the outer member back stops are removed or depressed out of the way if of an inset type or folded if hinged.

[0059] 12. A portable cutting system according to clause 1, when used horizontally the system is able to cut the ripped boards to length, using the 20mm holes for stops, the sliding measuring scale, adjustable guide supports, and repeat stops again repeatable cuts are possible. 13. A portable cutting system according to clause 1, the present invention can be used for cutting or routing multiple sheet materials including MDF, plywood, melamine, laminates, plasterboard, metal sheets, chipboard, and insulation board.

Claims

CLAIMS1. A cutting aid apparatus, said cutting aid apparatus including: first and at least second elongate members, arranged parallel to and spaced apart from one another; one or more movable guide support members provided on each of the first and second elongate members; said guide support members being movable along a length of the first and second elongate members; and a guide rail member arranged to rest on and / or abut first guide support members provided on the first and second elongate members, characterized in that at least one clamping member is provided on each of the first and second elongate members, arranged to clamp and retain a cut portion of material, in use.

2. A cutting aid apparatus according to claim 1, wherein the guide rail member locates, in use, between the movable guide support member and clamping member.

3. A cutting aid apparatus according to claim 1 , wherein said guide support members are also arranged, in use, to support and retain in position a board or panel of material to be cut.

4. A cutting aid apparatus according to claim 1, wherein at least first, upper and second, lower guide support members are provided on each of the first and second elongate members.

5. A cutting aid apparatus according to claim 4, wherein the first, upper guide support members are arranged to support the guide rail member, in use.

6. A cutting aid apparatus according to claim 1 , wherein said guide support members comprise a body portion, attached tothe respective elongate member; and a retaining portion, which extends from the body portion such that a space or gap is provided between the elongate member and retaining portion.

7. A cutting aid apparatus according to claim 6, wherein said guide rail member is arranged to locate on the retaining portion of the guide support members, in use.

8. A cutting aid apparatus according to claim 1 , wherein one or more tracks are provided on the first and second elongate members, extending along a length of a front face thereof.

9. A cutting aid apparatus according to claim 8, wherein said guide support members engage in slidable movement along at least one of said one or more tracks.

10. A cutting aid apparatus according to claim 1 , wherein said first and second elongate members include a measuring scale provided thereon.

11. A cutting aid apparatus according to claim 10, wherein said measuring scales are movable along said elongate members, as required by a user.

12. A cutting aid apparatus according to claim 1, wherein the first and second elongate members each include detachably attachable foot portions.

13. A cutting aid apparatus according to claim 12, wherein said foot portions are removable and reversible.

14. A cutting aid apparatus according to claim 13, wherein in a first arrangement, said foot portions are attached to the elongate members to enable the same to stand substantiallyvertically, in use; and in a second arrangement said foot portions are reversed and attached to the elongate members causing the same to stand at an angle relative to the vertical, tilted towards one another, in use.

15. A cutting aid apparatus according to claim 1 , wherein each of said first and second elongate members includes a first plurality of apertures formed in a front face and along a length thereof.

16. A cutting aid apparatus according to claim 1 , wherein said at least one clamping member on each of said first and second elongate members is located in and movable along one or more tracks, provided to extend along a length of a front face of the elongate members, and arranged to be secured in position as required by a user.

17. A cutting aid apparatus according to claim 1, wherein a plurality of slots or channels is provided in and along a length of a side edge or face of each of the elongate members.

18. A cutting aid apparatus according to claim 17, wherein said clamping member is locatable in and removable from a desired slot or channel as required by a user.

19. A cutting aid apparatus according to claim 1 , wherein said first and second elongate members include removable and replaceable front faces.

20. A cutting aid apparatus according to claim 1, wherein the first and second elongate members further include a back-stop member provided on a rear face thereof.

21. A cutting aid apparatus according to claim 1, wherein a second plurality of apertures is provided formed in a front face and along a length thereof.

22. A cutting aid apparatus according to claim 1 , wherein a third elongate member is provided, locatable in use intermediate, parallel to and in the same plane as the first and second elongate members.

23. A cutting aid apparatus according to claim 22, wherein said third elongate member includes at least one clamping member thereon.

24. A method of using a cutting aid apparatus as defined above, said method including the steps of: placing the first and second elongate members in a vertical orientation, spaced apart from one another and abutting a support surface; locating a board or panel of material to be cut between the first and second elongate members and retaining the same in position via the provision and securing of one or more guide support members on each elongate member; adjusting a first, upper guide support member on each of the first and second elongate members to a desired vertical position according to a cutting location of the board or panel of material; locating the guide rail member atop the first, upper guide support members, forming a cutting line along the board or panel of material; clamping an upper edge of the board or panel of material to be cut by at least one clamping member provided on each of said first and second elongate members; and cutting along the board or panel of material along a line defined by the guide rail member.

25. A cutting aid apparatus according to claim 24, wherein a third elongate member is provided and located in a vertical orientation intermediate the first and second elongate members.

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