Field of the Invention

This invention relates to a tool for cutting arcuate sections, especially for use in cutting arcuate sections in beams and joists, and conduits for those sections.

Background to the Invention

There is a need to cut half-round notches, or round-bottom cuts, in beams and joists in order to run facilities such as water, gas, electrics, data and other services. ladeed it is recommended under BS6891 that one should use a rounded bottom cut. Normally, where services are to be installed, one might create a flat-bottomed cut but cutting two substantially parallel lines into the beam and chiselling out the material inbetween the cuts. However, this results in a recess that is often much larger than the conduit being placed therein, thereby allowing it to move, which can be problematic. Additionally, because a section of a joist or beam has been removed, its structural integrity may be reduced, thereby leading to a risk of it failing. Furthermore, it results in a lack of insulation and protection for the conduit and can increase the risk of pipe creak and hydraulic hammer. Summary of the Invention

Accordingly, the present invention is directed to a hand tool comprising a cutter, the cutter comprising a shaft and at least one cutting edge arranged to extend beyond the exterior surface of the shaft, and the cutting edge being arranged to be substantially parallel with the longitudinal axis of a shaft. The cutter allows for a plunge cut to be made by aligning the shaft of the cutter substantially perpendicular to the material being cut. The use of at least one cutting edge arranged to extend beyond the outer surface and substantially parallel with the shaft provides a long cutting edge that can be used to create a half- rounded cut into material.

Preferably, the cutter is provided with plurality of cutting edges. This allows for a more even cut and reduces the time required to make the cut. Additionally, the hand tool is more balanced, in use. The cutting edges, preferably, extend along the longitudinal, or rotational, axis of the shaft and they may be substantially parallel with the longitudinal axis or a small way off therefrom. Whilst the cutting edges might be helical, when such a cutting edge is in use, it may induce undesirable motion relative to the material being cut. Clearly, where the tool is being used in a narrow space, movement towards a wall may cause damage to that wall.

Advantageously, the cutting edges extend along the majority of the length of the tool. By having the cutting edges extending a significant distance along the length of the tool, the cutting surface is increased, which allows for a quicker and smoother cut and also allows for a single plunge cut to be made to create the required recess. The rotation of the cutting edges around a central shaft allows for a half-round notch to be created in the material being cut. Therefore, an arcuate cut can be created.

It is advantageous that the tool further comprises an electric motor connected to the cutter for rotation thereof. Whilst the device may be manually operated, it is preferred that it is automated to decrease the time taken to make the required cut.

Preferably, the at least one cutting edge is releasable from the shaft, and, more preferably, a locking mechanism is provided to releasably retain the cutting edge in the shaft. By allowing the cutting edge(s) to be released from the cutter of the hand tool, a user can easily replace a damaged cutting edge. Additionally, the cutter may be retained in the hand tool so that the bearings allowing for rotation of the cutter are not disturbed when the cutting edges are changed. It may be desirable to use a least one grub screw on the, or each. This allows for quick and simple changing of the cutting edge(s). In such an arrangement, there may be an access hole in the region in which the cutter is retained to allow for the cutting edge being replaced to slide out of the shaft, particularly where a safety shield is employed. This may be particularly advantageous where the tool has contacted a metal screw or nail and become damaged. In an alternative embodiment, the cutting edge(s) may be fixed and could be made as a single, integral, piece with the shaft.

In a preferred arrangement, the axis of the shaft of the cutter, when in use, is substantially parallel with the material being cut. This allows for an effective plunge cut and to make the half-round notch.

The hand tool can be portable and used on beams and joists that are already in situ, rather than having to remove the beams.

The invention extends to a cutting system comprising:

a cutting tool as hereinbefore described; and

a clamp device for clamping the item to be cut.

Having a clamp to guide the tool allows a user to obtain a predictable cut and makes operation of the system easier.

In one arrangement, the cutting tool and the clamp device are a single unit. This allows for a hand tool that can quickly be attached to a piece of material and the cut made swiftly rather than having two parts that need to be engaged. Furthermore, by integrating the two parts, they are more easily located and can allow for one-handed holding of the complete system rather than needing to hold the clamp and tool separately.

Alternatively, the clamp device comprises a guide for receiving the cutting tool and the tool is adapted to engage the guide of the clamp. The system may comprise two separate parts so that the clamp can be applied and the tool guided by the clamp, which allows for a clearer view for the user when applying the clamp. The clamp and/or tool may comprise a laser in order to align the part(s) with the material to be cut. Attaching the clamp before making the cut provides a user with a predictable cut and holds the tool safely to reduce the risk of injury.

In one arrangement, the clamp comprises a threaded member to releasbly grip the material to be cut. Alternatively, the clamp may comprise a lever locking mechanism, which may be spring-loaded. Both mechanisms allow the clamp to be firmly applied to the material and aligned before making the cut.

The invention also extends to a conduit for supporting at least one pipe and/or cable, the conduit comprising a substantially U-shaped cross section. By providing a conduit that has a U-shaped cross-section, the services contained therein, which are usually circular in cross-section, can be safely retained. Additionally, with a round bottomed cut, the U- shaped conduit can engage the cut accurately and retain the services therein. The use of the conduit reduces the risk of pipe creak and hydraulic hammering.

The conduit further may further comprise a detachable lid. This allows the U-shaped conduit to be sealed, thereby allowing a surface to be placed over the conduit whilst protecting the services from damage. Furthermore, the use of a lid allows for the structural rigidity of the material that has been cut to be recovered by the lid spanning the gap and reinforcing the material. The lid ensures that the end of the material that has been cut is filled so increase the structural integrity.

Preferably, the conduit is provided with reinforced walls, and more preferably, the conduit comprises high density plastics material, particularly in the lid. This reduces the risk of a person accidentally drilling or cutting the conduit and associated. Additionally, or alternatively, the conduit, particularly the lid, may comprise metal.

Additionally, the invention extends to a cutter comprising a shaft and at least one cutting edge extending beyond the external surface of the shaft, wherein the at least one cutting edge runs substantially parallel with the shaft and along the majority thereof. Using a cutter with the edge extending along the majority of the shaft provides the ability to make a large plunge cut, thereby reducing the time required to make recesses in material for installing services. In one embodiment, the cutting edge is substantially permanently fixed to the shaft and the shaft and cutting edge may be integral with one another. By permanently fixing the shaft and cutting edge(s), the strength of the cutter may be increased and the risk of it becoming damaged may be reduced. The tool in which the cutter is placed may be provided with a bracket to allow simple replacement of the cutter should it become damaged.

In an alternatively embodiment, the at least one cutting edge is removable from the shaft. This allows simple replacement of a damaged or blunt cutting edge. It is advantageous that the cutter further comprises a locking mechanism to retain the cutting edges in the shaft. This may be by use of grub screws to attached the cutting edge(s) to the shaft.

The invention further extends to a method of cutting material as described herein.

Brief Description of the Drawings

An embodiment of the invention will now be described, by way of example only, and with reference to the accompanying drawings, in which:

Figure 1 is a view of a cutting edge for use with a tool according to the present invention; Figure 2 is a view of a shaft for use with the cutting edge of Figure 1;

Figure 3 is a view of a tool in accordance with the present invention;

Figures 4 and 5 show a cutting system according to the present invention;

Figures 6 to 8 show a conduit according to the present invention.

Detailed Description of Exemplary Embodiments 15 051436

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Figures 1 to 3 show a cutter 10 in the form of a bit for use with a hand tool. The cutter 10 comprises cutting edge 12 comprising a sharpened leading edge 14 and a connection edge 16. The connection edge 16 is formed as a flange extending in a different plane from the leading edge 14, such that the cutting edge loosely forms an "L" shape.

The cutter 10 further comprises a shaft 20 comprising a longitudinal groove 22 substantially parallel with the axis of the shaft 20. One end of the shaft 20 is provided with a grooved pulley section 24 to allow the cutting tool 10 to engage a belt to rotate the cutter 10, when in use. The other end of the shaft 20 is provided with an extension 26 to allow the shaft 20 to be held securely at that end.

To form the cutter 10, two cutting edges 12 are positioned into respective longitudinal grooves 22 of the shaft 20, as shown in Figure 3. The cutting edges 12 may be secured therein to restrict their movement.

Figures 4 and 5 show a cutting system 30 comprising a cutting tool 32 and a clamp 34. The cutting tool 30 comprises a cutter 10 is positioned within a motorised hand tool 36 (partially shown), with the motor positioned above the cutter 10, when in use. The cutter 10 is connected to the electric motor via a belt (not shown) via the pulley section 24 of the shaft 20. The cutting tool 32 further comprises a guide in the form of extensions 38a and 38b, which extend in a downward direction, when in use.

The clamp 34 comprises a material receiving section 40, which is formed by two, substantially parallel planar sections 40a and 40b. A first of the planar sections 40b is located at one end of the clamp and the second planar section 40a is spaced therefrom, creating a material receiving recess 40c therebetween in which material to be cut may be positioned. The first planar section 40b has a thickness of 10mm or less so that the cutting tool 32 can be positioned adjacent a wall. The position of the second planar section 40a relative to the first planar section 40b can be adjusted using a threaded member 42 to move it closer to or further from the first planar section 40a, in a similar arrangement as that used in a G-clamp. Adjacent the second planar section 40a is a gripping portion 44 to allow a user to grip the clamp 34 and through which the threaded member 42 passes. The top of the clamp 34 comprises a recess and two guide apertures B2015/051436

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46a and 46b that extend in the same direction as the planar sections. The guide apertures 46a and 46b and are located and sized to receive respective extensions 38a and 38b of the cutting tool 32, such that the cutting tool 32 engages the clamp 34. In use, the clamp 34 is attached to a material 48 by positioning the material 48 within the material receiving recess 40c and the threaded member 42 is rotated to clamp the material 48 within the receiving recess 40c. Once the material 48 is gripped securely, the cutting tool 32 can be positioned above the clamp 34 with the extensions 38a and 38b engaging the respective guide apertures 46a and 46b. The motor of the cutting tool 32 can then be operated to rotate the cutting tool 10. The cutting tool 32 is the moved further into the clamp 34 by moving the extensions 38a and 38b further into the apertures 46a and 46b. In moving the cutting tool 32 further into the clamp 34, the cutter 10 comes into contact with the material 48. In doing so, the sharpened leading edge 14 cuts into the material 48 and removes part of the material 48, thereby creating a half-rounded notch in the material 48.

The cutting tool 32 is pushed into the clamp 34 until the desired depth of cut is created in the material 48 or until the bottom of the cutting tool 32 contacts the upper surface of the clamp 34 and the extensions 38 can go no further into the guide apertures 46, as shown in Figure 5.

Figures 7 and 8 show a conduit 60, comprising a lower section 62 and a lid section 64. The lower section 62 has a substantially U-shaped cross-section base, or bottom section, to allow it to sit comfortable in a half-round notch cut recess and to accommodate a circular service pipe or cable 66 internally. The lid section 64 comprises a flat top 64a and an extension 64b that extends into the U-shaped cross-section of the lower section 62. The lower end surface 64c of the extension 64b is provided with an arcuate profile to engage the pipe or cable 66. When a pipe or cable 66 is positioned within the conduit 60, the lid section 64 is connected to the lower section 62. The lid section 64 and the lower section 62 may be provided with a snap-fit joining mechanism to allow the lid 64 to be retained on the lower section 62. 15 051436

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Figure 8 shows a conduit that is adapted to receive and hold two services 68, for example two pipes or a pipe and a cable.

Figure 6 shows a conduit engaged with material 48 that has been cut using the cutting system of Figures 4 and 5. The conduit is positioned within the cut material 48 and the U- shaped external profile of the conduit 60 fits into the corresponding U-shaped half-round notch cut into the material 48 by the cutting system 30.

Once the conduit 60 is in place in the material 48, a label may be applied to the lid section 64 of the conduit 60 in order to identify the service contained within the conduit 60. The label may be in the form of a sticker with different colours corresponding to the type of service contained within the conduit 60. Alternatively, or additionally, the conduit may be colour coded according to the service to be run therein. The lower end surface of the extension of the lid of the conduit may be provided with a yieldable material to allow that surface to adapt to the shape of the pipe or cable within the conduit.

The tool and the clamp mechanism may be joined so that the cutting system comprises single hand tool that can clamp and cut the material.

The clamp, being integral with the cutting tool or separate therefrom, may comprise a spring-loaded locking mechanism to grip the material. In such an arrangement, a lever may be used to engage and disengage the clamping mechanism.

The cutting tool may be provided with a laser to indicate where the cut will be made in the material. The use of the laser allows one to mark up the floor area to ensure a straight installation. The laser may be pivotal relative to the cutting tool to allow for an accurate alignment.

The clamp section of the cutting tool or system may be rotatable relative to the cutter or the cutting tool so that angled cuts can be made in the material. The front clearance of the cutting tool may be less than 15mm to allow the tool to be positioned against a joist running parallel to a wall to be cut easily, which is traditionally a difficult and time-consuming task using conventional methods. The conduit for positioning within the cut material may be sized so that the lid is flush with the top of the cut. Because the cutting system and conduit are used together, the measurements are predictable and the two can be made to work together. This reduces the risk of a rocking or loose floorboard.