Cutoff And Routing Device

Abstract

A precision cutoff and routing device including a support frame having locating and positioning elements thereon, with a cutting unit mounted for movement thereon which cutting unit includes material clamping members, a traversing cutting element and a plurality of routing devices which routing devices are arranged for controlled movement within a predetermined path for precisely routing a connector receiving recess in the bottom of the material being cut which recess may be formed on either side of the path of the traversing cutting element. Control means are provided to prevent movement of the routing devices through the path of the cutting element while the cutting element is moving.

Description

The problems of precisely cutting counter tops and the like particularly when the counter tops are to be joined to other similar sections are well known in the art. In order to provide proper miter cuts and further to properly locate the positions for the joining elements such that the installer will be able to satisfy the customer requires a high degree of precision cutting and more importantly the ability of duplication of the cutting on successive pieces of the top.

Applicant has provided herein a unique cutoff and mitering device which includes a routing system for precisely performing these requirements and which insures the same precise location of the routed connection without regard to the angle of the miter being cut.

It is therefore an object of applicant's invention to provide a cutoff device which includes a plurality of mitering positions to therefore provide a unit capable of precisely cutting counter tops and the like at various angles.

It is a further object of applicant's invention to provide a cutoff device for counter tops and the like which includes a routing system for forming a plurality of connector receiving recesses in the bottom of the counter top such that the cut tops may be effectively joined.

It is a further object of applicant's invention to provide a cutoff and routing device for cutting material such as counter tops and the like which includes a traversing cutting element and routing devices and means to control the same such that the routing devices may not be moved through the path of the traversing element when the traversing element is in motion.

It is still a further object of applicant's invention to provide a routing system for forming a plurality of connector receving recesses in the bottom surface of counter tops and the like which recesses are formed to permit connector tightening tools to be received therein.

These and other objects and advantages of applicant's invention will more fully appear from the following description made in connection with the accompanying drawings, wherein like reference characters refer to the same or similar parts throughout the several views, and in which:

FIG. 1 is a top plan view of a cutoff and routing device embodying the concepts of applicant's invention;

FIG. 2 is a side elevation thereof;

FIG. 3 is a front elevation thereof illustrating the control handles thereof in alternate positions with solid and dotted lines;

FIG. 4 is a vertical section taken substantially along Line 4--4 of FIG. 1 illustrating a control link in alternate, solid and dotted line positions;

FIG. 5 is a vertical section taken substantially along Line 5--5 of FIG. 1 and illustrating the several positions of the routing device in dotted and solid line positions;

FIG. 6 is a vertical section taken substantially along Line 6--6 of FIG. 1 and being drawn to an enlarged scale;

FIG. 7 is a vertical section taken substantially along Line 7--7 of FIG. 6;

FIG. 8 is a vertical section taken substantially along Line 8--8 of FIG. 1;

FIG. 9 is a vertical section taken substantially along Line 9--9 of FIG. 8;

FIG. 10 is a plan view of the connector receiving recess formed by the routing system; and,

FIG. 11 is a section taken substantially along Line 11--11 of FIG. 10.

In accordance with the accompanying drawings, applicant's cutoof and routing device is generally designated 10 and includes a lower frame portion 11 and an upper moveable and rotatably mounted cutoff unit 12.

The lower frame portion includes support legs 13 and a generally horizontal, arcuately formed track member 14 mounted thereon. This track member is substantially D-shaped and therefore includes an arcuately formed portion 14a and a straight, connecting section 14b. Arranged about the outer periphery of the arcuate section 14a are a plurality of positioning devices 15 which effectively hold the cutoff unit 12 in the selected arcuate position. These positioning devices 15 are in effect detent positions such that a biased pin element 16, carried by the cutoff section 12, will be received therein. Although many angular positions could be utilized, applicant provides the positioning devices for making 22 1/2.degree., 45.degree. and right angle cuts.

In order to properly locate a counter top or other material to be cut, applicant provides a back stop which, in the form shown, consists of a pair of spaced, vertically extending support members 17a, 17b arranged on the straight connector section 14b and having a rail member 17c extending therebetween. Obviously the pivotal mounting for the cutoff unit 12 must be directly in line with this back stop structure such that the proper miter will be formed.

The cutoff unit 12 includes a generally rectangular housing having sides 20a, 20b and rear and front ends 20c, 20d, The sides 20a, 20b provide a generally rectangular opening therethrough and within this opening a reinforced framework 21 is provided which framework again provides a generally rectangular passage 21a therethrough such that material to be cut may be fed entirely through the unit. This framework unit 21 must be sufficiently strong to withstand the clamping pressures necessary to hold the material being cut. A plurality of locating pads 22 are arranged on the lower portion of this frame 21 and a plurality of longitudinally slideable cylinder members 23 are mounted on the upper portion of the frame 21. The pads 22, rather than a continuous bed are provided to accomodate certain downwardly directed flanges that are provided on various counter tops. The spacing of these pads 22 is determined from the standard counter tops that are available on the market.

Arranged interiorally of the housing is the routing mechanism which is generally designated 25. This mechanism is shiftable from one to the other side of the center line of the housing, which center line is also the path of the cutoff saw to be described later, and on each of these sides the routing unit is movable in a preset pattern such that a connector receiving recess may be formed in the underside of the counter top at either end thereof.

The routing mechanism includes a plurality of electrically operated routers 26 which are carried adjustably on a first support plate 27 which support plate is rigidly secured to a control shaft 28. This control shaft is carried by a pair of spaced bearing blocks 29 and this shaft is capable of both rotational and longitudinal movement within these blocks. In order to best provide for such movement, particularly when working in an area where dust and particles from the material being cut exists, applicant has provided an air fitting in the block 29, designated 29a, such that air may be passed to the shaft receiving aperture 29b to blow out any such dust or particles.

Shaft 28 extends through the front end 20d of the housing and a cam follower 30 is secured thereto and extends upwardly therefrom to pass into a preformed cam surface defining plate 31 attached and extending forwardly from the housing. This plate 31 is provided with an opening which defines the permitted path of travel of the cam follower and which path will therefore be followed by the routers 26. With the shaft 28 being mounted for both rotation and longitudinal movement, the pattern illustrated in FIGS. 10 and 11 will be cut in the underside of the counter top. As shown therein, the cut recessed area R is generally triangular in shape with a connector section C extending therefrom to the edge of the counter. A standard connector would include a threaded member to be received into the connector section C with a threaded nut or the like to be placed into the recessed area R and tightened against the base of the triangular section. As shown in FIG. 11, the recessed area is radiused. This obviously is due to the rotational movement allowed to the shaft 28. This type of recessed area permits the insertion of tightening tools such as a socket into this area for ease of joining the sections. The radiused concept also removes less of the laminate supporting member than would be removed with a common depth cut thereby lessening the chance of damaging the counter when installing the same.

The routers 26 are prevented from crossing the cutting blade path when the same is moving by providing a stop unit 35 including a solenoid member 36 positioned above plate 31 and having on the actuating end 36a thereof, a stop bar 37 guided by a pair of upstanding pins 38. This stop bar will not allow the cam follower and thus the routers to cross the centerline of the housing and thus the saw path until the solenoid 36 retracts the stop bar 37 which will occur when the saw trips switches located at the ends of its travel.

A control handle 40 is pivotally attached to the extending end of shaft 28 with a yoke member 41 having a downwardly extending leg 41a with a slot 41b formed in such leg. A guide bar arrangement consisting of a pair of spaced support members 42--42 having a rod member 43 extending therebetween is arranged on the front end of the housing and the yoke leg 41a and slot position the handle with respect to the rod such that the longitudinal movement of the shaft 28 is obtained by pivoting the handle about this rod 43.

In order to shift the location of the entire routing mechanism 25, the entire shaft system, including the mounting blocks 29 are fixedly attached to a master control shaft 50. This shaft 50 is located on the centerline of the unit and is mounted for rotation by a plurality of bearing members 51 spaced along the bottom plate 20e of the housing and the bearing blocks 29 are fixedly attached to this control shaft such that the routing mechanism 25 may be shifted as illustrated in FIG. 4. Sets of stop blocks 52 are arranged on the bottom housing plate 20e and the router shaft 28 will contact the same. These blocks then serve as the positions on either side of center from which the routing operation will begin. A control handle 53 is arranged on the outwardly extending end of the control shaft 50.

A saw unit designated 55 is mounted for longitudinal movement on the housing and a pair of guide bars 56, 57 are respectively arranged on the upper portions of the housing sides 20a, 20b and a carriage unit 58 is arranged to slide on these guide bars. Applicant has found that one of these guide bars should be firmly attached to said side but that the other of such bars should be in relatively floating position thereon. The carriage member 58 includes bearings 59,60 and these may be what are known as adjustable or take-up bearings such that the carriage movement will be in proper alignment for the desired cut.

A drive motor 65, chain 66 and front chain idler sprocket 67 are provided for driving the carriage 58 both forwardly and rearwardly and although not shown in the drawings, applicant provides a control switch at either end of the travel of the carriage. These control switches will actuate the solenoid 36 to raise the stop bar 37 and allow the router unit to be moved past the centerline of the housing and further allow the routers to cut through the center line. During either forward or rearward movement of the saw carriage, this router motion cannot be achieved.

A driving motor 70 is mounted on the upper surface of the carriage 58 and as this is a moveable operation, a flexible connection 70a is provided from an upstanding conduit 71 to provide electrical energy to the motor 70.

Arranged below the carriage is the cutting saw 75. The mounting for this saw 75 is obtained with a first depending support member 76 having a flat mounting surface 76a at the lower portion thereof for mounting a bearing block 77 thereon. In order to provide for proper alignment for the saw blade 75 the bearing block 77 is adjustably mounted on the support 76 by providing enlarged apertures for receiving attachment means 78 therethrough and adjustment means including a downwardly depending flange 79 having one end thereof secured to the support 76 and having an adjustable member such as a cap screw extending through the other end to abut with the bearing block 77 such that the bearing block may be precisely located. Further adjustment may be obtained by providing the saw spindle 80 to be longitudinally shiftable within the bearing block 77. A drive belt 81 or other similar connection must be established from the motor 70 to the saw blade spindle.

In order to simplify the alignment process, a number of devices could be utilized without departing from the scope of the invention.

Obviously a control circuit must be established for the unit and this would include controls for carriage travel, saw motor control, material clamp controls, router motor controls and pneumatic controls for controlling the clamps and feeding air to the bearing blocks. All of these should be within the skill of those in the art and particularly when utilizing applicant's disclosure concerning the control switches at the ends of the saw travel to prevent the routers from crossing the saw path while the saw is in motion.

As stated, this unit is used for mitering and therefore the entire housing unit must be shiftable on the track 14. For this purpose, wheel structures 90, 91 are provided on the forward end of the housing and of course the rear of the housing must be rotatably attached to the support 11. This rotatable connection must be in line with the back stop structure.

The operation of the unit should be obvious to those skilled in the art. Material to be cut is inserted through the housing and the proper angle of cut is selected and the housing so shifted. The clamping occurs on only one side of the unit and therefore the proper clamps are activated. The saw motor and carriage travel motor are then activated and the cut is made. After such cut is complete the routing operation if required, may take place. This is accomplished by operation of the handle 40 to move the cam follower completely within the cam surface defined in plate 31. The plurality of routers will make all of the necessary connector recesses at one time. The material may now be released and removed from the machine.

It should be obvious that the applicant has provided a new and unique cutoff and routing device that will properly miter material to be cut if so desired and will insure a high degree of accuracy in such cut and will further provide a connector receiving recess in the underside of the material that will remove only a sufficient amount of material to permit connection while not weakening the material and will further permit the cutting of such recess according to a predetermined design and controlled location such that material cutoff and routed in this manner will be easily assembled.

Claims

I claim:

1. A cutoff and routing device for cutting counter tops and the like including:

a. a base providing a generally arcuate track area;

b. a housing mounted for rotation about a point on said base on one end of said housing and having track engaging means on the other end thereof;

c. a material passing aperture formed in said housing for positioning materials in a cutting and routing plane;

d. means for clamping the material in cutting and routing position;

e. a cutting member mounted for movement on said housing from one end to the other thereof to cut through the material in a cutting plane;

f. routing means underlying said material plane and shiftable into material routing position;

g. means for guiding said routing means to cut the underside of the material in a predetermined pattern; and,

h. control means preventing movement of said routing means through the path of said cutting member when said cutting member is moving from one end to the other of said housing.

2. The structure set forth in claim 1 and said housing including a pair of transversely spaced said support elements, said material passing aperture including apertures in each of said elements.

3. The structure set forth in claim 2 and a frame member carried in each of said side support elements, said frame defining said material passing aperture.

4. The structure set forth in claim 3 and said clamping means being adjustably carried by an upper portion of said frame members.

5. The structure set forth in claim 2 and track means provided on each of said side support elements, said cutting member being mounted for sliding movement on said track means.

6. The structure set forth in claim 5 and one of said track means being rigidly attached to one of said side support elements, the other of said track means being floatably mounted on said other side element.

7. The structure set forth in claim 1 and said control means including switch means on each end of said housing in position for actuation by said cutting member, retractable stop means positioned to engage said routing guiding means and prevent movement of said routing means through the path of said cutting member when said cutting member is moved from switch engaging position.

8. The structure set forth in claim 1 and said routing means including a first mounting shaft mounted for rotational and longitudinal movement having means for mounting router elements thereon in a first position relative to the material plane and on one side of said cutting plane and handle means for shifting said first mounting shaft in both rotary and longitudinal directions.

9. The structure set forth in claim 8 and said guiding means including a cam follower secured to said first mounting shaft and a cam plate defining an interior camming surface said cam follower being received therein.

10. The structure set forth in claim 8 and a second mounting shaft mounted for rotation on said housing and having bearing means secured thereon said first mounting shaft being mounted in said bearing means.

11. The structure set forth in claim 10 and said bearing means including means for introducing pneumatic pressure to the area thereof surrounding said first mounting shaft.

12. The structure set forth in claim 10 and handle means for rotating said second shaft to shift said first shaft to a second position on the opposite side of said cutting plane.

13. The structure set forth in claim 1 and said base having a plurality of angularly spaced locking positions and said housing being shiftable therebetween and lockable therein.