Tile Rebate Cutting Apparatus

The present invention relates to tile rebate cutting apparatus, and particularl ^y but not cx-iusively, relates to an apparatus for cutting rebaies on ^f .he peripSis^y of cr^isr-g tiles intended for use with suspended ceilings in offices and the like.

In such suspended ceilings, a framework formed of aluminium strips, arranged in a regular pattern to define squares each adapted to receive a tile or panel, is first secured in the desired position, and the ceiling tiles are then placed in the framework to provide a smooth ceiling in which recessed lights may also be incorporated. Typically, the tiles just rest on the framework and in many installations the framework projects below the general plane of the tiles. This is visually unattractive and the preferred option is to provide the tiles with a peripheral rebate which rests on the framework so that the face surface of the tile lies flush with the framework. The ceiling is thus given a visually smooth and attractive appearance.

However, rooms into which a suspended ceiling is fitted are extremely rarely the right size for the ceiling to need only square tiles of the fixed size. As a result, it is invariably necessary to cut the tiles down to fit the final space adjacent all four walls. As a result, the side of the tile which is being cut to reduce its size does not have a rebate and it is therefore necessary for the installer to cut such a rebate. Typically, with modern plastics ceiling tiles which are formed of an expanded or foamed plastics material, this is carried out by the operator using a sharp knife and straight edge to cut partially through the tile from its face to the depth of the rebate and then from the side edge to make another cut at right angles to the first to thereby cut away the material to form the necessary rebate. This method has the disadvantage that it is extremely slow and time consuming to make the necessary cuts and it is also difficult to ensure that the cuts are accurately positioned, with the result that the tiles can be spoilt causing unnecessary wastage, whilst the resulting appearance of the ceiling can be compromised. The use of a sharp knife such as a utility knife is potentially hazardous and is responsible for many accidents.

The present invention seeks to overcome or minimise these problems.

According to one aspect of the present invention there is provided a tile rebate cutting apparatus having a guide member forming a linear guide for a cutting tool, and a rebate

cutting tool incorporating at least two cutting devices, the rebate cutting tool being adapted to engage with said guide means to move along a predetermined line determined by the position of the guide means to enable a cut forming a rebate to be made in the edge of the tile, one cutting device being arranged TO make a first rebate CUT in the surface of a tile and the other cutting device being arranged to complete the rebate by making a cut in the edge of the tile at right angles to the first rebate cut which meets with the first rebate cut thereby to sever a piece of material from the tile to form the rebate.

Preferably, a further cutting tool is provided which is adapted to engage with the guide member and incorporates a cutting device positioned relative to the guide member so as to cut the tile to size, prior to the rebate being cut by the rebate cutting tool.

Preferably, the guide means comprises an elongate member having at least one raised guide rail extending along its length. Preferably, two such raised guide rails are provided arranged in spaced parallel relationship.

Preferably, the or each cutting tool has an elongate groove or recess adapted to engage with the rail or rails on the guide means.

In a preferred embodiment, the guide means is formed of an aluminium extrusion and the or each cutting tool has a main body formed of an aluminium extrusion.

The cutting device may comprise a fixed blade the cutting depth of which may be adjustable but preferably, the cutting device or devices comprise rotatable cutting wheels which may be diamond tipped.

According to a second aspect of the invention there is provided a rebate cutting tool incorporating at least one cutting device, the rebate cutting tool been adapted to engage with a spirit level to move along a predetermined line determined by the position of the spirit level to enable a cut forming a rebate to be made in the tile.

In a preferred embodiment of the invention, the tool has a chassis engageable with the guide means so as to be slidable therealong, the chassis carrying a cutting tool carrier

having a body pivotally mounted on the chassis so as to be pivotal between a tile cutting position and a rebate cutting position.

Preferably, ths carrier has ε first tile cutting part and a second rebate cutting part angularly positioned with respect to the first part, the arrangement being such that when one of the parts is in its cutting postion, the other part is pivoted to a position in which its cutting devices are clear of a tile being cut.

The relative positions of the cutting devices on the carrier may be adjustable.

The apparatus may have a drive motor for driving the cutting devices, which may be a battery powered electrical motor

Prefarbly, the guide means comprises an extrusion of constant cross section, and the chassis has a mating cross section engageable therewith, the cross sections being such as to enable the chassis to slide along the guide means but to be contrained against movement in the lateral planes.

Preferred embodiments of the present invention will now be described by way of example with reference to the accompanying drawings in whictr-

Figure 1 shows a schematic perspective view of a rebate cutting tool in accordance with the present invention,

Figure 2 shows a further cutting tool for cutting a tile to size,

Figure 3 shows a guide member for the cutting tool's,

Figure 4 shows the underside of the guide member,

Figure 5 shows an alternative embodiment of the invention,

Figure 6 shows a tool for determining the cutting line for a rebate

Figure 7 shows a perspective view of a further embodiment,

Figure 8 shows a side view of figure 7, and

Figure 8 shows a preferred embodiment of a guide tool for determining the cutting line on a tile.

Referring now to Figures 1-4 of the drawings, there is shown in Figure 1 a rebate cutting tool 1 for cutting a rebate along one edge of a ceiling tile of the type which is typically formed of a foamed or expanded plastics material. The cutting tool 1 consists of a main body 2 typically formed of extruded aluminium, which has two downloadly open channels 3 arranged in spaced parallel relationship separated by a base element 4 of the main body. The two channels 3 are adapted to engage with two guide rails 5 located in spaced parallel relationship on a guide member 6 (see Figure 3), which again may be formed from an aluminium extrusion. On its underside, the guide member 6 has strips of a material 7 such as rubber bonded to or inset the guide member to provide the guide member 6 with a non- slip underside. Many other forms of non-slip surface may be provided.

As shown particularly in Figure 1, the rebate cutting tool 1 has a further base element 8 aligned with the base element 4 located on one side of one of the channels 3. At its free end, the further base element 8 has a downwardly depending web 9 which serves as an abutment arranged to butt up against the side edge of a ceiling tile to position the cutting tool 1.

The tool 1 includes a first cutting device 10 in the further base element 8 which is adapted to form a cut along a line in the surface of the tile which is a predetermined distance required by a rebate from the edge of the tile. A further cutting device 11 is located in the downwardly depending web 9 which is adapted to form a cut along a line in the edge surface of the tile to meet up with the cut formed in the surface of the tile to enable a portion of material to be removed to thereby form a rebate along the edge of the tile which is such as to enable the tile to fit into a framework of a suspended ceiling so that the tile lies flush with the surface of the ceiling framework.

The cutting devices 10, 11 in the embodiment shown comprise rotatable wheels, which may be diamond tipped, it is also possible in an alternative form for the cutting devices to comprise cutting blades which may be of the replaceable type as used in a Stanley (Registered Trade Mark) knife. The cutting depth of the blades, or of the wheels, may be- adjustable by means not shown) to suit different thicknesses of tile or size of rebate required.

Figure 2 shows a similar cutting tool in which like parts bear like references. This cutting tool 12 comprises a parting off tool which is designed to cut a ceiling tile to size. It has two downwardly open channels 3, as in the rebate cutting tool, and in the further base element 8 has at least one, and preferably two, as shown, parting off wheels, reference 13 and 14.

In operation, the guide member 6 is secured to a ceiling tile by a clamp or even by manual pressure, and the tile is cut to size by means of the parting off tool 12. Then, without having to reposition the guide member 6, the rebate forming tool is used to cut a rebate in the new edge of the tile. Again, although rotatable cutting wheels are illustrated, the tool may have a fixed blade as described above with reference to the rebate cutting tool. The depth of cut may be adjustable to suit different thicknesses of ceiling tile.

Referring now to Figure 5 there is shown an alternative embodiment of the invention in which the rebate cutting tool 1 is adapted to engage a guide member formed by a spirit level 15. The spirit level 15 is of the type formed of an l-section aluminium extrusion and has two opposite machined faces 16, 17.

In this embodiment, the rebate cutting tool 1 has a downwardly open groove or channel 19 which is adapted to engage over one crosspiece 18 of the l-section, as shown. The tool has a planar face 20 adapted to abut the machined face 16 of the spirit level and dimensioned so that when the tool is placed with its channel engaged over the edge of the spirit level as shown, a base element 21 of the tool rests on the surface of the tile to be cut. Thus, by moving the tool 12 along the spirit level 15 a rebate can be cut as before. Similarly, a corresponding parting off cutting tool may be provided.

In an alternative embodiment (not illustrated), the cutting tool has a large downwardly open channel with two inwardly opposing flat faces which are adapted to engage over the

machined faces of the spirit level. In yet another embodiment, the spirit level is designed to be used in the upright position with one machined face resting on the surface of a tile with the cutting tool being adapted to rest on the upper machined face and to engage the sides of the machined face.

Referring now to Figure 6, there is shown a tool for determining the precise position for cutting the line in dependence upon the size of the opening in the ceiling track which needs to be filled by a tile. The tool consists of two elongate side members, 22 and 23, which are joined by two transverse members 24 and 25 which are telescopic to enable the spacing between the two side members to be varied. As shown, the transverse members have three telescopic sections, 24a, 24b, 24c and 25a 25b and 25c. A manually operable clamping not 26 is shown for clamping the telescopic member 25 in a desired position and a similar knob is preferably provided for the transverse member 24. The two telescopic sections 24a and 24b pivotally connected to the side members 23 by means of pin joints 27 and 28 to enable the side member 23 to be displaced and given the relative to the side member 22.

At the lower end as shown in the drawing, a recess 29, and 30 is formed in the end face of each of the side members which recess is adapted to slide onto the track of the suspended ceiling. This end of the side members, there is a depending abutment 31 and 32 respectively. At the other end of the side members 22 and 23, rebates 33 and 34 are formed

In operation, it is often necessary to cut a tile to size to fit into a non regular space between the main track framework of the suspended ceiling and the wall of the room. With this tool of the present invention, the recesses 29, 30 are first of all inserted onto the track section extending away from the wall and the side member 22 is pushed up against the track section spaced from the wall. The rebate 33 and 34 at the other end of the side members about the edge of the opposing track section extending away from the wall. The side member 23 is then manually pushed up against the track section secured to the wall. If the wall is at an angle, the side member 23 pivots about the pivots 27 and 28 to lie at an angle to the side member 22. The manually operable clamping screws 26 are then tightened on the two transverse members 24 and 25. In this way, the precise line along which the tile must be cut and the rebate formed is determined. The tool is then removed

from the track and placed on the tile with the abutment 31 and 32 abutting the edge of tile the tile can then be cut accurately to size and the rebate formed.

At the turning now to Figure 6, there is-shown ε cutting too! 35 in which the operations of cutting a tile to size and cutting a rebate are combined into one tool. The apparatus is provided with a base board 36 carrying on its underside friction pads 37 which serve to hold the base member on a tile without slipping. The base board 36 carries an elongate guide member 38 formed of an aluminium extrusion, although it could be formed of a plastics material. The cutting tool 35 has a chassis 39 which is adapted to engage and slide along the guide member 38. The cross-sectional profile of the guide member 38 is engaged by a mating cross-sectional recess in the chassis 39 so that the chassis 39 is slidable along the member 38 but is constrained against any lateral movement in either plane.

The chassis 39 carries a body comprising a cutting tool carrier 40 which is pivotally mounted on the chassis 39 so as to pivot between a tile cutting position shown in Figure 6 for cutting a tile to size and a rebate cutting position as shown in Figure 7. In the position shown in Figure 6, the carrier has a rear, tile cutting part 41 having a lower planar face 41a which rests on the chassis 39 so as to be essentially in a horizontal position relative to the plane of the base board 36. This part 41 of the cutting tool carries two rotatable cutting wheels 42 and 43 which are rotatable about axes parallel to the plane of the base board 36 to thereby be enabled to cut a tile to size about a plane normal to the plane of the tile. The depth of cut of the first wheel 42 is less than that of the second wheel 43, the wheel 42 being of smaller diameter which thus serves as a pilot cutter to cut part way through a tile so that the larger cutting wheel 43 will then complete the cut through the tile. In this embodiment, the axes of the two cutting wheels 42 and 43 are fixed relative to the face 41a and hence the face of a tile but it is possible in other embodiments that the axes of rotation of these two cutting members relative to the base board are adjustable to accommodate tiles of different thicknesses.

Referring now to Figure 7 also, the carrier 40 has a forward, rebate cutting, part 44 having a lower planar face 44a inclined upwardly at an angle relative to the face 41a. The carrier part 44 has a rebate cutting wheel 45 with an axis parallel to, but spaced from, the axis of rotation of the cutting wheels 42 and 43 and projects from the lower face of the carrier to

the extent required to cut the depth of a rebate. The cutting line of the wheel 45 is set back from the cutting line of the wheels 42, 43 to provide the correct inset for the rebate without having to re-position the tool. Although shown as a fixed axis, it is possible in certain embodiments that the position of this axis is ^' adjustable relative to the base board 36 to thus provide different depths of rebate cut. The position of the wheel 45 along the axis may also be adjustable to alter the size of the rebate. The carrier part 44 also carries a lateral rebate cutter cutting wheel 46 which is rotatable about an axis 47 normal to the plane of the base board 36 to make a rebate cut in the side edge of a tile. The carrier part 44 carries an adjusting device 48 to adjust the position of the cutter 46 relative to the base board 36 to enable the position of the rebate cut in the side of a tile to be adjusted in dependence upon the thickness of the tile and the size of rebate required. The horizontal cutter wheel 46 is enclosed by a cover 49 apart from its cutting section. When the carrier 40 is tipped forwardly about its pivot axis, the face 44a abuts the upper horizontal face of the chassis 39. In this position in the cutting wheels 45 and 46 are in a position to cut a rebate and the wheels 42 and 43 are lifted clear of the tile being cut, as shown in figure 7.

In operation, to cut a tile to size, the base board 36 is placed on the tile at the desired location, the cutting tool 35 is positioned on the rear edge of the base board 36 and thee chassis39 engaged with the guide member 38. The operator places the base board 36 on the desired position on a tile and then manually presses down on the rear part 40 of the cutting tool and pushes it along the guide member to thereby sever the tile. The operator then pivots the cutting tool to the rebate cutting position shown in Figure 7 and draws the tool back across the tile which enables the two cutting wheels 45, 46 to form the rebate.

In this embodiment, the cutting wheels are freely rotatable, but it is envisaged that in a further embodiment, the wheels are rotatably driven by an electric motor connected to the cutting wheels through a gear train or a toothed belt. It is envisaged that the drive to each section 41 , 44 may be disconnected when the part 41 or 44, as the case may be, is not in the cutting position. The electric motor is preferably powered by a rechargeable battery. This embodiment is particularly useful for cutting heavy duty tiles, particularly those formed of heavier, denser material such as plasterboard or similar gypsum-based materials.

Referring now to Figure 8, there is shown from an underside view, a guide tool for determining the cutting line for the size of a tile, and the related rebate, for those tiles,

typically against a side wall of the ceiling which do not accommodate a full tile. The tool has two parallel spaced elongate side members 50 and 51 which are adjoined by a first crossmember 52 carrying a locking mechanism 53 and a second crossmember 54 spaced from the first cross member 52. The crossmember 54 projects upwardly beyond the upper.* faces 50a and 51a of the side members 50, 51 and has at its upper free edge, a horizontally extending lip 54a which is adapted to engage over the ceiling frame member spaced from the wall where the non-standard size tile is to fit. Each of the side members 50 and 51 has slidably located therein and projecting from one end an elongate spacing member 55 and 56 respectively. At their free ends, the spacing members 55 and 56 carry abutments 57 and 58 respectively which, in operation, are adapted to abut the part of the ceiling frame secured to a wall. Although not shown, the ends carry markers such as a pin which serve to mark the tile at the cutting stage to provide a cutting line. A further cross piece 59 which incorporates a lost motion device 61 serves as a guide to help keep the two members 55 and 56 in the correct location relative to each other, but its principal purpose is to serve as a hand hold to enable both members 55 and 56 to be moved simultaneously with one hand, even though they might need to be moved by different amounts. In operation, the tool is held with one hand on the transverse member 52 and the other hand holding the cross piece 59. The tool is then offered up to the ceiling framework and the crossmember 54 is arranged to abut the frame element spaced from the wall with the lip 54a engaging over the framework to accurately locate the tool.

The locking mechanism 53 includes on each of the spacing members 55, 56 an elongate toothed rack 61 , only one of which is shown, which is engaged by a tongue located in the transverse member 52 and biased into engagement by resilient means (not shown). The tongues are lifted out of engagement with the racks 61 by depressing a lever mechanism 62 in the transverse member 52. This can thus be done with the one hand which is holding the device in position, leaving the other hand of the operator free to move the spacing members 55, 56 out to abut the opposing frame element as described previously. The lever mechanism 62 is then released so that the spacing members 55, 56 are locked in position relative to the transverse member 54. The device is then placed on the tile to be cut with the transverse member 54 abutting one side edge of the tile. The marker points on the ends 57, 58 of the space members 55, 56 thus mark the tile at the correct location for the tile to be cut and a rebate formed by the cutting tool described earlier.

It will be understood that the embodiments described by way of example only and that alternative forms of the apparatus possible. For example, in rjό further form of the invention, the cutting tool may have three cutting wheels rotatable about spaced parallel, axes, two of the cutting wheels performing the function of cutting the tile to size, as in the cutting wheels 42, 43, the third cutting wheel being adapted to form the rebate cut in the face of the tile simultaneously with the tile being cut to size. The tool is then pivoted to a position in which the edge cut to form the rebate is made on the nex^pf the tool. This pivotal movement could be about an axis parallel to the axis of movement of the tool along the guide means.