The invention to which this application relates is apparatus for use in the cutting of substrates such as a single or multi layer panel and particularly, although not necessarily exclusively, substrates in the form of insulation boards and/or other boards which may be used in the building industry and which are hereinafter referred to in a non-limiting manner as panels.

In one embodiment the panels may be used for forming a layer of a wall, flooring and/or ceiling of a building in order to allow an insulating effect to be created between the exterior of the building and the interior of the living space.

The panels typically come in a range of predetermined sizes and typically, panels of a particular kind or group, will have a uniform thickness so that the panels can be placed with their edges abutting to form substantially uniform internal and external facing surfaces and to provide a substantially uniform insulating effect across the wall, floor and/ or ceiling. However, as the panels are typically provided in uniform predetermined sizes, there is a need to be able to cut the same so as to allow the overall combination of panels to match the dimensions of the floor, wall or ceiling to which they are to be fitted.

Conventionally, the cutting of the panels is to provide one or a number of straight- line cut edges to be provided and may include straight-line cuts provided at different angles so as to form a panel of a particular shape so as to be located in a corner, under a stairwell or the like, with the aim being to provide the external edges of the panel substantially flush with the adjacent edge of the ceiling, wall or floor so as to create the optimum fit so that, for example, if the panels are provided for the purpose of insulation, the insulation effect is maximised.

The cutting of panels of this type is conventionally achieved by a person scribing or drawing the line of cut onto the panel, mounting the panel on a secure surface such as a clamping apparatus or workbench and the person then uses a saw to cut along the line as accurately as possible so as to cut the panel to the required shape. While this does achieve the desired cut, problems arise in that the cut may not be as accurate as desired which therefore requires further work to be performed and the manual cutting operation itself takes time and physical exertion especially when one considers that a large number of said panels may be required to be cut at any given time. Furthermore, the cutting of the material can generate significant quantities of dust which can be harmful, especially to those with breathing problems. Furthermore, it is found that the material from which the insulation panels are formed, can be particularly problematic to the person performing the cutting operation and may create health hazards to the person performing the cut and/ or other persons who are in the surrounding environment.

Conventionally, in order to try and minimise this problem, the person who performs the cut may be required to wear a mask, other protective items such as gloves, and/ or dust extraction apparatus may be required to be installed at the premises at which the cutting operations are performed but, in practice, it is found that this is often not put into practice, or any dust extraction apparatus which is provided may be blocked or not operable.

The aim of the present invention is therefore to provide apparatus for use in cutting panels and in particular, panels of insulating material which allow the cut to be achieved relatively quickly, with a minimum physical effort, and with a reduced time. A further aim is to perform the cut in a manner which allows a reduction in the quantity of dust or debris which is created when performing the cutting operation and therefore improve the environment in which the cutting operation is performed.

In a first aspect of the invention is provided a cutting apparatus, said apparatus including a base, an elongate member having a first end attached to the said base and a second, free end which is provided to be moved by a user when performing a cutting operation, said base having a surface onto which a substrate which is to be cut is placed and said elongate member is attached to the apparatus via a retraction mechanism so that the said free end is gripped and moved away from the retraction mechanism and, with the substrate located on the base for cutting, the said free end is operated by the user to move the elongate member upwardly and towards the retraction mechanism so as to move the elongate member through the substrate to form a cut line along and through the said substrate. Typically, the substrate is a panel and the cutting operation forms the panel into two portions.

Typically, the panel is located with respect to the base so that a guide line formed on the panel is substantially in line with the passage of movement of the elongate member so as to allow the cut to be performed accurately and in line with the guide means formed on the panel.

Typically, the free end of the elongate member is provided with or as a handle which can be gripped. Typically when the handle and free end have been moved away from the retraction mechanism the same are located and retained in a first position at a first end of the base by a retaining means and in which case the elongate member is extended and lies to a first side of the panel once the panel is placed in position for cutting and the said free end is moved from said first position towards a second position at which the retraction mechanism is located, typically at or towards an opposing second end of the base and the elongate member lies to the opposing side of said panel such that the movement of the handle back to the retraction mechanism, allows the elongate member to cut fully through and along the said panel.

In one embodiment the elongate member passes from a retained position substantially flush or located in the base to apposition above the external face of the panel as free end is moved towards the retraction mechanism.

Typically, the retraction mechanism is spring biased so as to bias the handle and elongate member towards the retraction mechanism location at the second position.

Typically, the retraction mechanism includes a roller spindle around which the elongate member is wound when at the second position.

In one embodiment, the elongate member is a wire and the handle is secured to the said wire. In one embodiment, the base has a first surface onto which the panel is placed and a second opposing surface which is placed onto a support surface such as a floor, table or the like.

In one embodiment, the base is provided to permanently locate the retraction mechanism at the second position and the retaining means allow the selective retention of the handle at the first position.

In one embodiment, the first and second positions are provided at a permanent fixed distance apart. Alternatively, the first and second positions are adjustable. In one embodiment the retaining means for the elongate member free end and/ or handle can be moved to a selected one of a range of positions on the base and locked in that position. In another embodiment the base is formed of a plurality of portions, with at least one portion movable with respect to the other portion or portions so as to allow the distance between the first and second positions to be adjusted and then fixed for use. In one embodiment a first portion includes the retraction mechanism and is slidably movable with respect to a second central portion and a third portion includes the retaining means and that portion is slidingly movable with respect to the second central portion. The ability to adjust the distance between the first and second positions allows different dimensions of panels to be accommodated between the first and second positions and therefore allows the same to be adjusted on site for the particular tasks which are to be performed.

In one embodiment, the retaining means is a hook portion into which the handle or a protruding portion on the wire may be placed so as to releasably retain the elongate member at the first position against the force being applied by the retraction mechanism. When the handle is gripped, the elongate member and handle can be moved to release the same from the retaining means and with the handle gripped the force of the retraction mechanism aids movement of the elongate member through the panel to cut the same.

Typically the apparatus includes guide means which can be placed onto the face of the panel opposing the face of the panel which is in contact with the base so as to act as a guide so as to ensure an accurate cut through the panel in position with the base during the cutting operation. In one embodiment the guide means define a passage through which the elongate member passes during the cutting operation.

In one embodiment the guide means also act as clamping means to retain the panel in position or, alternatively, additional clamping means may be provided. Preferably, the said clamping means are releasably engaged by spring-loaded retaining clips to a locating means.

In one embodiment the base includes a cutting member, said cutting member raised above the surface of the said base so as to perform an initial cut of a panel during use. The elongate member is then able to pass through the initial cut of the panel to perform the cutting operation.

In one embodiment, the cutting member is fixed to the surface of the base. In another embodiment, the cutting member is retractably located within the base of the apparatus, such that the cutting member may be actuated through the surface of the base to perform the initial cut.

In a further aspect of the invention, there is provided a method of forming a cut line on a substrate, said method comprising placing a cutting apparatus on a support surface, moving an elongate cutting member to an extended, first position on the base on or adjacent to a first surface of the base and retaining the same in that position via retaining means, placing onto a first surface of the base of the apparatus, a substrate which is to be cut, aligning the substrate with respect to the base so as to ensure that the line of cut which is to be performed on the substrate is along the desired path, and wherein once the substrate has been aligned with the base, releasing the elongate member from the retaining means, gripping a free end of the elongate member and moving the elongate member through and along the substrate to form the cut line therethrough and return the elongate member towards a retracting mechanism at a second position on the base such that when the elongate member is substantially retracted, the cut line is formed.

Typically the first and second positions are respectively located on opposing sides of the panel when placed in position to be cut. In one embodiment, the elongate member is provided as a wire and has a free end at which a handle is located for gripping and, at the opposing end, means are provided to attach and wind the said elongate member around a spool of the retraction mechanism.

Typically the retraction mechanism includes biasing means which bias the handle back to the retraction mechanism and the biasing means aids in the movement of the elongate member through the panel to form the cut line in the same.

Specific embodiments of the invention are now described with reference to the accompanying drawings wherein:

Figure 1 illustrates a base of the apparatus in accordance with one embodiment of the invention;

Figure 2 illustrates the apparatus of Figure 1 in elevation with a panel in position to be cut;

Figure 3 illustrates the apparatus of Figures 1 and 2 with the apparatus being used to form the cut line along the said panel; and

Figure 4 illustrates the apparatus of Figures 1-3 in a form in which the cut line has been formed through the panel and the panel portions have been removed.

Figure 5 illustrates a second embodiment of the apparatus in a form in which the cut line has been formed through the panel and the panel portions have been removed.

Referring firstly to Figure 1, there is illustrated apparatus 1 in accordance with one embodiment of the invention in which the apparatus includes a base 2 having a first surface onto which a panel 4 is to be located and a second, opposing surface 6 provided to be located on a support surface 8 such as a floor, table or the like. At a first position 10 on the base, there is provided retaining means 12 and at a second position 14 at the opposite end of the base there is provided a retraction mechanism 16 and from which extends an elongate cutting member 18 which is attached at one end to the retraction mechanism 16 and is provided at the opposing, free end, with a handle 22. A guide means 20 is also provided to provide a guide channel 23 for the passage of the elongate member 18 therethrough so as to guide the movement of the elongate member and hence control the accuracy of cut through the panel from the surface 24. The guide means can also act as a clamping means to retain the panel in position on the base 2.

In one embodiment the bars which define the guide channel 23 are held together by, in this embodiment, a number of magnets which hold the two guide rails together but at the same time allowing the guide channel 23 to be retained so as to allow the elongate member 18 to still freely pass through and along the passage to perform the cut accurately through the panel. Typically the end 25 of the channel 23 is open so as to allow the elongate member to leave the channel and continue its path to the retraction mechanism 16. Typically the height of the guide means 20 is adjustable as indicated by arrow 42 to then be fixed in a position so as to allow the same to be close to and/ or exert a clamping force on, the panel surface 26. The guide means 20 may be retained in the fixed position by a spring-loaded clip 46.

In Figure 2, the elongate member 18 is shown extended such that the handle 22 and free end are located at and retained by the retaining means 12 at the first position 10 and the elongate member lies substantially flush with the surface 24 of the base. In this position, the apparatus is ready to be used to perform a cut. The panel 4 which is to be cut is placed in position so as to lie between the said first and second positions 10,14 and typically, a guideline will have been formed on the panel so as to indicate the location at which the cut line is desired to be formed through the panel to form the same into two portions.

The guideline can then be aligned with guides on the base and the clamping bar 20 is placed onto the surface 26 of the panel.

With the panel in the desired position, the user can then grip the handle 22 to release the same from the retaining means 12 and also allow the biasing spring of the retraction mechanism 16 to act on the elongate member 18 to encourage the same to move back towards the retraction mechanism 16 at the second position 14. With the user gripping the handle, and the force of the retraction mechanism, the elongate member wire 18 is encouraged to pass through and cut the panel along the guideline and Figure 3 illustrates the cut through the panel having been partially formed with the shaded part 28 of the panel having been cut.

The continued movement of the elongate member and handle 22 in the direction of arrow 30 back towards the retraction mechanism at the second position, achieves the entire cut line through the panel so as to cut through the panel completely as indicated in Figure 4 and the handle 22 is now positioned adjacent to the retraction mechanism 16 at the second position 14.

Thus, an efficient clean and quick cut is formed through the panel using the apparatus in accordance with the invention.

In order to return the apparatus to a position to perform the next cut in the next panel, the handle 22 is gripped and moved in the direction of arrow 40 back towards the retaining means 12 at the first position 10 and then moved to be located with the retaining means and thereby allow the next panel to be placed in position.

Although in this embodiment, the distance between the first and second positions on the base can be fixed, it should be appreciated that the base may be formed of a number of adjustable portions and, or locating means 36, 38 on the base may be adjustable as indicated by arrows 32, 34 so as to allow the relative distance between the first and second positions 10,14 to be adjusted and then locked in position when the appropriate distance has been achieved within a range of possible distances and this thereby allows the apparatus to be range taking in terms of the panel sizes which may be placed between the first and second positions. The locating means 36, 38 may include a clamping means 48 moveable along a direction 50 as indicated in Figure 5. The clamping means 48 are provided to be located on the upper surface of the panel 4 to be cut, the clamping means exerting a retaining force on the same. The clamping means 48 may include selectively located by spring-loaded retaining clips 46.

In a further embodiment as illustrated in Figure 5, the apparatus may include a small blade 44 mounted on the base surface 24. The blade 44 provides a preliminary incision into the panel 4 when the same is located on the base, providing an initial cut such that the elongate member wire 18 may pass through the panel more easily, and resulting in a cleaner cut. The blade 44 may be mounted to the upper surface of the base 24, or may be mounted on a retracting mechanism such that the blade is housed within the base, and raised from the surface of the base 24 to perform the incision when required.