Note: Descriptions are shown in the official language in which they were submitted.
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WOODWORKING METHOD AND APPARATUS
Field of Invention
This invention relates to a method and apparatus for cutting material and
joining material and particularly relates to a method and apparatus for
cutting and
joining wood utilizing a tool having an abrasive sleeve, said tool having in
one
embodiment a bearing surface following a template for cutting said wood, and
said tool having in another embodiment an abrasive sleeve adhering to a
cylindrical body by a solvent-free adhesive.
Background Art
Various devices and methods have heretofore been designed and utilized
for cutting and joining materials together such as wood or the like. Routers,
drills,
table saws, scroll saws as well as other machines and tools may cut these
materials.
For example U.S. Patent No. 5,114,265 relates to an interlocking joint for
joining two panels together having curved jigsaw shaped indents and
protrusions
on edges of both panels that fit together and can not be pulled apart. The
indents
and protrusions are cut by a router with a straight-sided cutter. A template
is
provided for guiding a bushing on a cutter shaft of a router and the template
takes
into account the bushings having a larger diameter than the cutter. There is
also
a jig provided that has fingers that are assembled to cut out the interlocking
joint
with a router.
U.S. Patent No. 5,267,593 teaches a spindle arranged for mounting
cutters to an associated router configured to include a lower shaft co-axially
aligned with an upper shaft having an abutment collar therebetween. An upper
threaded boss mounts a fastener assembly to secure and position the sharper
cutter between the abutment cutter and the upper shaft threaded boss.
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Other arrangements are shown in U.S. Patent No. 5,038,636, which
relates to a jig and workpiece transport mechanism for making a curvilinear
cut
with a conventional band saw which continuously linearly translates and
rotationally reorients a jig and an attached workpiece to maintain the saw
line on
the cutting edge in the workpiece aligned with the band saw blade.
Yet another arrangement is shown in U.S. Patent No. 1, 948,266 which
relates to a holder for an abrasive stick comprising a hollow supporting
member
terminating in a tapered end portion, said member being longitudinally slitted
whereby to render it compressible and said tapered end portion having a
bayonet
slot therein, and means fitted over the tapered end portion compressing the
tapered end to retain an abrasive stick therein, the means includes an element
adapted to co-operate with the bayonet slot to retain said means fitted over
said
tapered end.
Furthermore U.S. Patent No. 5,682,935 relates to a template utilized in
conjunction with a rotating cutting tool such as a router bit to form a self-
mating
repeating interlocking pattern in the edge of a workpiece. The template has a
body having an elongated edge having a plurality of notches formed therein.
Each notch as two sides and an innermost edge, the notches being spaced along
the elongated edge at equal intervals. Each notch has at least one S-shaped
side, which has an outer curved portion and an inner curved portion, the
radius of
the inner curved portion being equal to three times the radius of the outer
curved
portion. The rotating cutting tool is spaced apart from the elongated edge of
the
template by a distance equal to the radius of the outer curved portion of the
S-
shaped sidewall so that as the cutting tool is guided along the edge of the
template an interlocking self-mating pattern is formed in the workpiece edge.
Other arrangements are shown in U.S. Patent No. 4, 405,004 which
teaches a dovetail fixture for guiding a cutting tool and cutting mortises and
tenons while U.S. Patent No. 4,607,673 relates to a dovetailed fixture for
clamping and holding two workpieces and for guiding a cutting tool whereby
mortises are cut in one workpiece and tenons are concurrently cut in the other
piece.
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Finally U.S. Patent No. 5, 193,596 relates to a pattern cutting assembly
having a pattern guide member used to co-operate with a pattern and a
workpiece holding frame which in turn has a workpiece member mounted thereon
and used in conjunction with a rotating blade, such as a router blade or a
scroll
saw blade, to cut a predetermined accurate pattern within the workpiece
member.
These and other prior art devices and apparatus present relatively
complicated methods and apparatus, which do not provide consistent and
accurate reproducible methods of cutting and joining materials together.
Furthermore U.S. Patent No. 5,114,265 utilizes a template which takes into
account a bushing having a larger diameter than the cutter, where the cutter
bites
into the wood and thereby provides relatively inaccurate means of cutting the
materials.
Moreover scroll saws utilized in the prior art have cutting blades which
reciprocate up and down but tend to wander from side to side.
It is an object of this invention to provide an improved method and
apparatus for cutting materials such as wood or the like, as well as joining
material such as wood or the like.
It is a further object of this invention to provide improved tools for use in
association with said method and apparatus which include improved means for
accurately cutting said materials.
Disclosure of Invention
It is an aspect of this invention to provide a tool for milling materials said
tool having a cylindrical portion and an abrasive cylindrical means, and a
solvent-
free adhesive intermediate said cylindrical portion and said abrasive
cylindrical
portion.
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It is an aspect of this invention to provide a method for joining two
materials together comprising providing guiding means for guiding a shaping
means for shaping said materials, joining said materials together.
It is a further aspect of this invention to provide a tool adapted to contact
a
template for shaping materials to a desired shape comprising a body having
means for connection to means for revolving said tool; abrasive cylindrical
means
removably securable to said body; means for contacting said template for
shaping said material.
It is yet another aspect of this invention to provide a method of joining a
first piece of material having a selected shape to a second piece of material
having a second selected shape which registers with said first selected shape
comprising cutting a first and second template having selected first and
second
shapes; securing said first and second templates to first and second materials
where said first and second materials peripherally extend beyond said first
and
second templates respectively so as to define excess material; removing said
excess material from said first and second material with a tool having a
cylindrical
portion, an abrasive tube having an internal diameter registrable with said
cylindrical portion, cylindrical shoulder for rotating contact with said
template
whereby said abrasive tool removes said excess material as said cylindrical
shoulder contacts and moves along the peripheral edge of said template and
thereby produce said materials having selected registrable shapes.
Brief Descrption of Drawings
Fig. 1 is a top plan view illustrating one embodiment of the invention.
Fig. 2 is a top plan view of a template.
Fig. 3 is a top plan view of a template.
Figs. 4a and 4b are top plan views of wood to be shaped.
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- Fig. 5 is a perspective view of a drill press where the top integral bearing
of the tool engages a template.
Fig. 6 is a perspective view of a drill press where the bottom integral
bearing of the tool engages a template.
Fig. 7 is a perspective view of a router where the top integral bearing of
the tool engages a template.
Fig. 8 is a perspective view of a router where the bottom integral bearing
of the tool engages a template.
Fig. 9 is an exploded view of the tool.
Fig. 10 is an exploded view of another embodiment of the tool.
Fig. 11 is an exploded view of another embodiment of the invention.
Fig. 12 illustrates a tool with a scroll saw.
Fig. 13 is an exploded view of another embodiment of the tool.
Best Mode for Carrying Out the Invention
In the description that follows, like parts are marked throughout the
specification and the drawings with the same respective reference numerals.
The drawings are not necessarily to scale and in some instances proportions
may
have been exaggerated in order to more clearly depict certain features of the
invention.
Figure 1 shows an example of a desired finished product, which can be
produced in accordance with the method and apparatus to be described herein.
An inlay 2 having a desired shape may be comprised of a suitable material such
as oak or the like which is to be inlaid into another material such as maple
4: The
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invention to be described herein can be utilized to produce any desired shape
and the example shown in Figure 1 herein is shown for illustrative purposes
only
and shall not be construed to limit the invention herein. For example the
method
and apparatus can be utilized for inlays, marketry, intarsia, or the like.
In order to produce a desired pattern as shown in Figure 1 a guiding
means 6 such as a template or pattern must first be produced as shown in
Figures 2 and 3. The inlay 2 will be produced by a template or guiding means
while the receiving wood 4 will be produced by the template or guiding means
8.
The templates 6 and 8 are produced from a material, which is easily cut
but durable enough to guide a tool to be particularized herein. Suitable
materials
consist of door skin material, veneer, arborite or the like. In one embodiment
one
can overlay the door skin material with arborite or the like so as to give the
pattern rigidity and long lasting qualities. The template 6 is cut from such
door
skin material or veneer by suitable means such as a scroll saw (not shown);
and
the template 6 will correspond to the desired shape. Furthermore the template
8
is also cut from the door skin material by suitable means such as a scroll saw
(not shown) or the like. The templates 6 and 8 may by way of example be cut in
a scroll saw by utilizing a OIsonT"" universal #5 blade (which is 0.016 thick
and
0.038 inch width) so that the templates 6 and 8 are accurately cut to close
tolerances.
Thereafter a rough-cut of the inlay 2 may be cut from a piece of material
such as oak 12 as shown in Figure 4a. The rough cut of the material 14 is
again
cut in a suitable saw such as a scroll saw (not shown) so that the exterior
extent
of the rough cut 14 is slightly larger than the desired finished shape 2 as
represented by the phantom lines in Figure 4a.
Thereafter the template 6 is attached to the rough cut 14 and secured
thereby by suitable means such as double sided tape or the like. The double-
sided tape will firmly secure the template or pattern 6 to the rough cut 14
representative view of which are shown in Figures 5 and 6.
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Figures 5 and 6 also illustrate a suitable machine such as a drill press
which may be utilized in order to shape the rough cut 14 and produce the inlay
2.
However one should appreciate that other machines may also be used such as a
router disclosed in Figures 7 and 8, where the speed of router or other is
less
than 2000 rpm, and preferably 1725 rpm.
The typical drill press shown in Figures 5 and 6 includes a table 16 which
will support the rough cut 14 and the template 6. As described previously the
template 6 is firmly secured to the rough-cut 14 by suitable means such as
double-sided tape sandwiched between the template 6 and rough-cut 14.
Thereafter the template 6 double-sided tape (not shown) and rough-cut 14 may
be moved in unison relative to the top of the table 16. The table 16 includes
a
suitable hole 18, which is adapted to receive the shaping tool to be described
herein. The shaping tool 20 is illustrated in the exploded view shown in
Figure 9.
The shaping tool 20 comprises a shaping means 22 which consists of a
cylindrical hollow tube having an abrasive surface 24 that is adapted to be
received by the shaping tool body 26. In particular the shaping tool body 26
includes a first cylindrical portion 28, which has an internal threaded hole
30 at
one end 32 thereof. The first cylindrical portion 28 is adapted to be tightly
received within the hollow tube of the cylindrical tube of abrasive 24 as
shown by
the arrows in Figure 9, where the internal diameter is treated with a solvent-
free
compound before the abrasive cylinder is installed unto the cylinder portion
28 of
the body of the tool so as to stop the abrasive cylinder from skating relative
the
body. A solvent-free compound is used so that once the abrasive cylinder is
spent or used the abrasive cylinder may be easily removed. An example of a
solvent-free compound is contact cement; but other solvent-free compounds
could be used.
The outside diameter of the first cylindrical portion 28 and the inside
diameter of the tube 24 is closely toleranced so that the first cylindrical
portion 28
when treated with the solvent-free compound referred to earlier fits snugly
and
tightly within the inner diameter of the tube 24. Thereafter a cylindrical end
cap
34 is firmly secured to the first cylindrical 28 in a manner whereby the
abrasive
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tube 24 is disposed between the end cap 34 and shoulder 36 so as to secure the
shaping means 22 between the end cap 34 and shoulder 36. The end cap 34 is
cylindrical in shape and includes a protruding cylindrical extension 38 which
is
adapted to be received within the counter bore 40 disposed at one end of the
first
cylindrical portion 28. This ensures that the end cap 34 is co-axially
disposed
about the central axis 42 of the tool 26. Suitable means such as a screw 44 is
then utilized so as to secure the abrasive tube 24 between the end cap 34 and
shoulder 36. The end cap 34 defines an integral bearing surface.
Figure 6 illustrates the assembled tool shown in Figure 9.
The tool shown in Figures 6 and 9 is superior to the cutter disclosed in
U.S. Patent No. 5,114,265.
The shaping means 22 comprises an abrasive material such as silicon
carbide or the like having a grit which can range from 24, 36, 50, 80-100 as
well
as 100-150 or more.
Moreover the outside diameter of the end cap 34 and shoulder 36 define
an integral bearing surface and are dimensioned so as to be identical or
substantially the same. Furthermore the outside diameter of the integral
bearing
24 is:
(a) oversize - which means that the outside diameter of the abrasive
cylinder 24 is less than the outside diameter of end cap 34 and
shoulder 36; or
(b) flush - the outside diameter of the abrasive cylinder 24 is
substantially the same as the outside diameter of end cap 34 and
shoulder 36.
The lower integral bearing is available with an oversize bearing which
compensates blades thickness used in cutting patterns. For example if an Olson
#5 blade is used the thickness of the blade and hence the keef is 0.016 thick,
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the oversize bearing is then made to correlate with the blade thickness, ie
the
outside diameter of the integral bearing is 0.016 larger than the outside
diameter
of the abrasive cylinder, that is the radius of the integral bearing is 0.008
larger,
so as to compensate for the blade thickness. This allows one to obtain
substantially a mirror image of the insert 2 with material 4.
One will utilize the oversize tool on the pieces, ie the piece being inserted
2 or the piece receiving 4 the insert 2 or vice versa, but not both when using
an
insert.
Generally speaking the coarse grit sizes such as 50 or finer are used with
an oversized integral diameter since these grit sizes will be used to further
shape
or mill the rough cut 14 so as to "mill" the oversized shape of the rough cut
14 to
the desired shape 2 in a manner to be described herein. Furthermore the finer
grit sizes such as 80-100 are generally flush since they will be used to
finely mill
the oversized material 14 to the desired shape 2 in a manner which shall now
be
described.
The assembled tool 20 also includes a mandrel 42, which is designed to
be received by the chuck 46 of the drill press 48 as shown in Figure 6. A '/2
inch
chuck will receive a '/Z, 3~s, '/4 mandrel or any mandrel less than '/z inch.
In the
example shown in Figure 6 the template 6 is adjacent the tabletop 16 while the
rough-cut 14 is disposed above the template 6. In such arrangement the end cap
34 is adapted to eventually contact the peripheral edge of template 6 as a
person
manipulates the template 6 which is stuck to rough cut 14 and slidingly moved
along the top of the table 16. At the same time the shaping means 20 revolves
at
a suitable speed such as for example between 500 and 2000 rpm and preferably
between 1725 and 2000 rpm so that the abrasive cylinder 24 mills the perimeter
of the rough-cut 14. In the arrangement shown in Figure 5 the integral bearing
34
eventually contacts the peripheral edge of the template 6. Since the integral
bearing 34 is comprised of material such as brass or the like the abrasive
surface
24 will no longer bite into the rough-cut 14. Thereafter the template and
rough
cut 14 is manipulated so that the shaping tool 20 shapes the rough cut 14 to
the
desired shape 2 which corresponds to the template 6.
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Depending on the amount of material to be shaped the excess material 50
which is represented as the material located between the peripheral edge 14
and
2 shown in Figure 4 one may utilize a coarse grit or a fine grit as outlined
above.
Figure 5 is a representative view, which operates in a manner similar to
that shown in Figure 6 except that now the shoulder 36 is utilized to contact
the
peripheral edge of the pattern or template 6.
Figures 7 and 8 are representative views, which operate in a manner
similar to that described in Figures 5 and 6 but in relation to a router.
Generally
speaking the router rotates at much higher speeds than drill presses and
therefore it will be appropriate to step down the rpms to a suitable range.
However the invention is not limited to any rpm and higher or lower speeds may
be utilized, so long as the pressure applied to the material being handled
will not
overheat the tooling. Preferably the rpm is operable between 1725 and 2000.
Moreover a variety of different radiused tools 20 may be utilized depending
on the desired shape and intricacy of the material to be milled. For example a
variety of different sized tools may be used such that the outside diameter of
the
integral bearing 34 and 36 may be for example one inch in diameter, 3/4 inch,
5/8
inch, '/4 inch, ~~s inch or the like. However smaller or larger sizes can be
used
including oversize.
Furthermore once the rough cut material 14 is shaped to the desired
shape 2 one may separate the template 6 from the inlay 2 by means of prying
with a knife edge or the like. Thereafter another desired shape may be
produced.
For example one may cut the piece 8 from a piece of material 13 as shown in
Figure 4b whereby the hole 15 is cut slightly smaller than the desired shape
4. In
this case the tool 20 will be inserted into the recess 17 and used to mill the
material to the desired shape 4 by removing the excess material 51 defined by
the material between the rough cut 17 and the desired shape 4
Thereafter the inlay 2 may be inserted into the material 4.
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In the process described above the template 6 is cut from the piece of
door skin material such as veneer or the like as described above such that the
remaining piece 8 defines the other desired shape. In this case one ensures
that
the inlay 2 will fit tightly within the material 4 since the two are cut at
the same
time particularly when utilizing a #5 blade. Since the template 6 and 8 fit
snugly
with one another the inlay 2 fits snugly within the material 4.
Although the template material has been described in relation to door skin
material or the like which is approximately 3/16 of an inch thick, other
suitable
material can be used so as long as the templates produce a stiff durable
peripheral edge whereby the integral bearings 36 and 34 contact.
Furthermore the shapes illustrated in the drawings are for illustrative
purposes only and may include any desired shape such as two sinusoidal pieces
contacting one another. Furthermore two straight edges may be produced by
utilizing the method and apparatus described herein so as to produce
substantially perfect abutting edges that may be glued together.
Once the inlay 2 and material 4 have been cut and shaped as described
above suitable sealants and adhesive may be utilized so as to permanently glue
the inlay 2 into the material 4. The method and apparatus described herein
produce substantially clean flush fitting pieces.
In the embodiment of tool shown in Figure 9 the bearing surface 36 may
be flush as described while the bearing surface 34 is oversize as described;
alternatively bearing surface 34 may be flush while bearing surface 36
oversize;
or both bearing surfaces 36 and 34 being flush or oversize as required.
Moreover Figure 10 illustrates another embodiment of the tool 20 which
includes only one bearing surface 36, cylindrical body portion 28 and abrasive
cylinder 22. The tool 20 shown in Figure 10 operates in the same fashion as
the
tool disclosed in Figure 9 except only one bearing surface is utilized. The
abrasive cylinder 22 is secured to the cylindrical portion 28 by means of a
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solvent-free adhesive or compound so as to prevent skating of the cylinder 22
relative to the body 28 during normal rotation of the tool in the drill press
or router
as described above. Again once the abrasive surface 22 is spent the abrasive
may be easily removed by notching one end of the abrasive 22 and unraveling
the cylindrical surface 22 from around the bronze cylindrical body 28. Any
remaining solvent-free compound on the cylindrical portion 22 may easily be
removed by firmly wiping the cylindrical surface since it does not permanently
bond to the surface 28 as in case of a solvent-based compound. The solvent-
free compound tends to remain flexible yet sufficiently adherent between the
abrasive surface 22 and the body portion 28 so as to prevent skating under
normal operating conditions. If one tends to ram the abrasive cylinder 22
against
the wood with great force it would likely cause either ripping abrasive
surface 22
or skating of the abrasive surface 22 relative to the body 28, and this must
be
avoided.
Moreover figure 11 illustrates another embodiment of the tool 60 which
may be utilized in association with a scroll saw 62. More particularly the
tool 60
comprises of a cylindrical body portion 64 having a first outside diameter.
The
opposite ends of the cylindrical body portion 64 include a first cylindrical
extension 66 and a second cylindrical extension 68. Cylindrical portions 64,
66,
and 68 are co-axially orientated as shown. In the embodiment shown in Figure
11 the cylindrical extensions fib and 68 are fixed relative to the central
body
portion 64. The tool 60 also includes an abrasive tube 70 which is hollow
having
an inside diameter which is adapted to firmly slide against the outside
diameter of
the cylindrical body portion 64. As in the case of tool 20 a solvent-free
compound
is applied to the inside diameter of abrasive cylinder 70, or to the outside
diameter of body portion 64 and the two pieces are slid one over the other so
that
the abrasive cylindrical portion 70 overlays the cylindrical body portion 64.
Once
the solvent has sufficiently secured the abrasive cylindrical portion 70 to
the body
portion 64 both extension 66 and 68 may be secured to the scroll saw as shown
in Figure 12. Thereafter as the scroll saw reciprocates up and down the
abrasive
surface 70 can be utilized to mill desired surfaces in an accurate and
efficient
manner.
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Since the tool 60 comprises of a rigid structure the tool 60 may mill desired
shapes without wandering as in the case of blades which are heretofore
utilized
with scroll saws.
Moreover figure 13 is a partial view of another embodiment of the tool as
shown in Figure 11 except that both extensions 66 and 68 are adapted to freely
rotate relative to the body portion 64 in the following manner. In particular
opposite ends of the cylindrical body portion 64 each include an annular
recess
72 which are adapted to receive a rotationally sliding cylindrical portion 74
having
an annular groove 76. The extension 66 is fixedly secured to the cylindrical
portion 74. Moreover the outside cylindrical surface of the cylindrical body
portion 64 includes a hole 78 which is adapted to receive a pin 80 or the
like.
The pin 80 is designed so as to extend into the annular groove 76 and permit
the
cylindrical portions 74 to radially rotate about the axis 82. Both ends of the
embodiment shown in Figure 3 include a similar structure. Moreover the tool as
shown in Figure 3 also includes the abrasive cylindrical surface 70 which
adheres
to the outside of the cylindrical body 64 by means of a solvent-free compound.
Thereafter the tool as shown in Figure 13 may be attached to a scroll saw in a
similar fashion as that shown in Figure 12. As the tool shown in Figure 13
reciprocates up and down in the scroll saw the abrasive surface 70 along with
the
cylindrical body portion 64 will tend to rotate about the axis so as to
present a
fresh surface for milling a piece of material.
Advantages which are realized by utilizing the invention described herein
include:
1. shaping or milling tools which do not bite into or rip the material as
may be experienced in the cutter disclosed in U.S. Patent No.
5,114,265;
2. fine intricate fitting parts may be produced by utilizing abrasives
having finer and finer grits;
3. the abrasive surface may be easily changed if worn;
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4. smaller diameter shaping tools may be utilized for intricate shapes;
5. method and tools utilized herein are versatile and may be used to
produce two mating straight edges, two irregular shapes or inserts;
6. the tool utilized herein produces smooth accurate shapes for both
shaping parallel to the grain or cross-grain.
l0 Suitable abrasives are silicon carbide or diamond grit.
Various embodiments of the invention have now been described in detail.
Since changes in and/or additions to the above-described best mode may be
made without departing from the nature, spirit or scope of the invention, the
l5 invention is not to be limited to said details.
Although the preferred embodiment as welt as the operation and use have
been specifically described in relation to the drawings, it should be
understood that
variations in the preferred embodiment could be achieved by a person skilled
in the
:?0 trade without departing from the spirit of the invention as claimed herein
