Abstract:
A cutting too for making arcuate cuts in a stone or ceramic material work piece uses a rotary cutting tool mounted on a pivoting radial arm with the plane of the cutting tool perpendicular to the radial arm. Rotation of the radial arm moves the cutting tool in an arcuate path producing an arcuate cut in the work piece. The cutting head may be indexed to the work piece by means of a screw or stepping device.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     The benefit of the earlier filing date under 35 U.S.C. 120, of Provisional Application 60/596,062, Filing Date: Aug. 29, 2005, is claimed for this application. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention is in the field of stone, tile and other ceramic, cutting devices.  
       BACKGROUND OF THE INVENTION  
       [0003]     Title and stone cutting is a well know practice, as shown in archeological ruins as known in the modern world. Tile setting, whether in antiquity or in our modern era, and as seen in most tile installations, is in rectilinear patterns with tiles preferably comprised of straight edges, as the easiest and most accurate way of cutting tile in pieces to fit a pattern. However, instances arise where the pattern requires tile be cut in a precise curved or arcuate pattern, meaning in a pattern with one or more arcs of difference respective radius and center locations.  
         [0004]     In these instances, the tile cutter must resort to hand cutting of the precise arc, or small pieces, small enough to define a curve when placed in a pattern and to mesh into an adjoining pattern. As is well known in the art, any mis-cuts, prevents a smooth placement of the cut tile on the first try and could leave uneven open spaces, spoiling the pattern&#39;s overall appearance.  
       SUMMARY  
       [0005]     The disclosed inventive principles, as shown for a disclosed preferred embodiment, eliminates the problems of accurately cutting arcs in stone or tile, or other hard or ceramic material, by hand and enables an efficient machine cut of a precise arc, of varying radius and arc circumferential lengths, in a curvilinear pattern, as may be required in fitting one more pieces of tile cut in radian related arcs or radian circumferential lengths, over into a meshing or adjoining arcuate pattern.  
         [0006]     An object of this invention is a tile or ceramic or other hard surface cutting tool that can be moved in a repeatable arcuate path over a work piece for making arcuate cuts in the work piece.  
         [0007]     An object of this invention is a tile or ceramic or other hard surface cutting tool, that can be arranged to make precise arcuate cuts in paths varying in radius or radians, or circumferential arcuate lengths.  
         [0008]     Another object of the invention is a tile or ceramic or other hard surface cutting tool, that can be indexed into the work piece to make progressively deeper cuts as the cutting tool is moved in a repeatable arcuate path, enlarging the arcuate cut until the work piece is separated into the arcuate cut finished piece and the remaining stock.  
         [0009]     The disclosed invention, as shown by the disclosed inventive principles, is able to control the cutting of a precise arc, or radial distance according to a preset radius and arc length and angle traversed or the radian arc traversed.  
         [0010]     According to a preferred embodiment, a rotary cutting blade is mounted on a radial arm with the plane of rotating blade substantially perpendicular to the radial arm longitudinal axis.  
         [0011]     The radial arm is mounted for pivoting movement about an axis through a shaft bearing located proximate a work support surface. Locating the bearing for the radial arm shaft proximate the work surface, allows a more precise alignment of the rotating cutting blade at its point of cutting contact with the work surface, with the center of the axis of rotation of the radial arm and a more precise cut arc, all of which is the object the invention.  
         [0012]     As shown in a preferred embodiment, the radially mounted cutting head supporting a cutting blade, is rotated about the axis of rotation through the radial arm support shaft, moving about the axis and cutting an arc and an arcuate path, in the tile or stone, or other ceramic work surface, at the point of contact of the cutting blade with the work. An indexing head is provided for movement of the cutting blade on the cutting head, substantially in an indexing direction parallel to the axis of rotation of the radial arm and progressively into the work piece, to allow a progressive cutting of the work as the indexing head and the blade is arcuately rotated through an arc of a desired radial distance.  
         [0013]     An alignment support device comprised by the cutting head is disclosed in two separate pieces with a first alignment plate located at one end of the radial arm opposite the axis of rotation. The purpose of the alignment plate, as shown in a preferred embodiment, is to permit the alignment of the cutting head support plate for the cutting tool and the cutting tool, substantially with the plane of a planar cutting tool perpendicular to the radial arm longitudinal axis and with the plane of the planar cutting tool aligned parallel to the indexing direction into the work piece.  
         [0014]     In this way a substantial advantage is obtained as a minimum point of contact of the too cutting surface with the work surface can be made, consistent with a smoothly cut arc, as would be known to those skilled in the art of cutting hard material like stone, or ceramics.  
         [0015]     As shown for a preferred embodiment, the indexing head may be arranged with a screw for continuous or progressive advancement of the head components down toward the work surface, as with each successive pass of the radial arm and the cutting head in the preferred intended arc or the indexing head may be arranged for a downward progressive movement of the cutting tool, in steps with an incremental control adjusted for the work hardness, the type of cutting tool or blade and the depth of cut desired for each radial pass of the cutting head.  
         [0016]     The advantage of the radial arm arcuate cutting tool, as shown and described in a preferred embodiment, are repeatable precise arcuate cuts in a hard stone or ceramic material by the combined rotation of the rotating cutting surface through the locus of a preset arc or radial distance, while progressively indexing the cutting too or blade downward and deeper into the arcuate cut, to finish the cutting process.  
         [0017]     What is shown and described in a preferred embodiment is a cutting tool or blade for making arcuate cuts in tile or other ceramic or hard materials comprising, a radial arm means; first means for supporting the radial arm means for movement about an axis of rotation; the radial arm means comprising second means for supporting a planar cutting tool; the second means comprising third means for indexing movement of the second means in an indexing direction toward a work piece; the second means comprising means for supporting the cutting tool or blade with the plane of the cutting tool orthogonal to the radial arm, for cutting an arcuate path in response to the movement of the radial arm means about the axis of rotation, and in response to the indexing movement of the third means.  
         [0018]     In the disclosure of a preferred embodiment, is shown the second means comprises a support plate means and an alignment plate means; the support plate means comprises means for mounting the cutting tool; and wherein the third means is mounted on the alignment plate means for the indexing movement of the support plate means, relative to the alignment plate means. The means for indexing comprises means for progressively indexing the first means, and the means for indexing, comprises means for continuously moving the first means into a work piece.  
         [0019]     Additionally shown in a preferred embodiment is the alignment plate means comprises means for rotational movement of the support plate means and the means for indexing comprises means for rotating the cutting tool in the plane of the cutting tool, about the means for rotational movement, through an arcuate path in a indexing direction to or from the work piece and in a plane orthogonal to the axis of the radial arm means and parallel to the axis of rotation.  
         [0020]     The support plate means is shown as comprising means for movement of the support plate means in the indexing arcuate path and comprising means for clamping the support plate means in a set position within the arcuate path. As disclosed, the third means comprises a support plate means and an alignment plate means and means for mounting the support plate means for movement relative to the alignment plate means in the indexing direction; and wherein the third means comprising means for driving the cutting tool in the arcuate indexing direction in the arcuate path of a slot in the support plate means.  
         [0021]     As disclosed in a preferred embodiment, the arcuate indexing direction is in a plane, substantially perpendicular to the radial arm and the alignment means comprises means for mounting the third means on the alignment means. The disclosed means for driving the cutting tool in the arcuate indexing direction, comprises a shaft means; means for moving the shaft means in the axial direction of the shaft means, and means on the support plate means for following the movement of the shaft means displacing the support plate in the arcuate indexing direction and through the arcuate path.  
         [0022]     The operation of the disclosed system is for making repeatable arcuate cuts in a tile or other ceramic surface, comprising, a planar rotating cutting tool; the rotating cutting tool comprising a cutting edge in the plane of the rotating cutting tool; a radial arm with a radial arm axis extending along the radial arm.  
         [0023]     The cutting tool is mounted on the radial arm; and the radial arm is mounted in the bearing for axial rotation about the axis of the bearing; the rotating cutting tool mounted on the radial arm for rotation in an arcuate path about the bearing axis. The rotating cutting tool is mounted on the radial arm with the radial arm axis passing through the plane of the rotating cutting tool and he radial arm axis is orthogonal to the plane of the rotating cutting tool.  
         [0024]     As shown in a preferred embodiment, a cutting head is mounted on the radial arm; the cutting tool mounted on the cutting head; the cutting head comprising a movable support plate and an alignment plate.  
         [0025]     The alignment plate is mounted on the radial arm, supporting the support plate; an indexing tool is arranged with a first part connected to the alignment plate and a second part connected to the support plate; the rotating cutting tool is mounted on the support plate. The indexing tool mounted on the alignment plate for displacement relative to the alignment plate and for moving the support plate in response to the displacement.  
         [0026]     The indexing tool has a first part comprising a support for a shaft mounted on the alignment plate for movement of the shaft along the axis of the shaft and second part comprising a support for the shaft on the support plate for movement of the support plate in responses to the movement of the shaft. The support plate may be mounted on a rotational axis on the alignment plate for rotational movement and the support plate comprises an arcuate slot radially opposed to the rotational axis; and clamps disposed in the arcuate slot and cooperating with the arcuate slot for clamping the support plate to the alignment plate. In this arrangement, the displacement of the indexing head is parallel to the axis of rotation of the radial arm and wherein the radial arm axis is substantially perpendicular to the plane of the rotating cutting tool.  
         [0027]     Additionally shown for a preferred embodiment is a method for making repeatable and progressively deeper arcuate cuts in a tile or ceramic material comprising the steps of, mounting a rotating planar cutting tool on a radial arm mounted on an axis of rotation, with the plane of the cutting tool perpendicular to the direction of the radial arm and parallel to the axis of rotation of the radial arm; indexing the cutting tool in the plane of the cutting tool and in the direction of a work piece and moving the radial arm to cause the rotating cutting tool to arcuately engage a work piece to make an arcuate cut. The method may comprise the steps of mounting the rotating planar cutting tool comprises the step of mounting an alignment plate to the radial arm; mounting a support plate on for indexing movement on the alignment plate and mounting the rotating cutting tool on the support plate and wherein the step of indexing the cutting tool comprises the step of continuously indexing the cutting tool. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0028]      FIG. 1  shows in a schematic perspective view, a preferred embodiment of the disclosed invention.  
         [0029]      FIG. 2  shows in a schematic view, the cutting head support plate  
         [0030]      FIG. 2   a  shows in a schematic partial view, the cutting head support plate indexing screw and its pin for insertion into an aperture in the alignment plate.  
         [0031]      FIG. 3  shows in schematic form, and in a top view, the support plate juxtaposed with the alignment plate and arcuate movement of the cutting blade in an arcuate path about the axis of the radial arm supporting the cutting blade.  
         [0032]      FIG. 4  shows in schematic form, the back surface of the alignment plate, with the direction shown for the insertion of the pin shown in  FIG. 2   a.   
     
    
     DESCRIPTION OF THE INVENTION  
       [0033]     The invention is shown generally in a schematic perspective view  11 , as comprising a work support surface  13  on which a tile or other stone or ceramic work piece may be supported proximate a cutting too  15 . The cutting tool  15  is shown in a preferred embodiment as a planar rotating cutting blade  15  with a cutting edge at the periphery of the cutting blade, as would be well known to those skilled in the art. The cutting tool is mounted for rotating movement by motor  17 . As would be apparent to those skilled in the art, the rotating cutting tool  15  is circular with the cutting edge of the rotating cutting blade tool located in a plane, at the periphery of the rotating cutting blade  15 .  
         [0034]     For the purpose of explanation with reference to a disclosed preferred embodiment, the planar cutting tool  15  may be referred to as a cutting tool or blade or rotating cutting blade or rotating cutting tool, all referring to any suitable cutting tool as would be known to those skilled in the art. The cutting head may be referred to as comprising the alignment plate  33 , and support plate  31  with the indexing means for progressively displacing the cutting tool  15  toward the work piece  12  on worktable  13 .  
         [0035]     A radial arm  19  with a radial arm axis is shown supported on a shaft or column  21 . The shaft  21  is mounted for substantially free rotation within bearing  23  mounted within the work support surface  13 . The position of the radial am  19  relative to an axis of rotation  16 , as shown in  FIG. 3 , of the shaft  21  in bearing  23 , and radius of the arc made by the cutting blade  15 , mounted at the end of the radial arm  19 , may be adjusted, as shown in a preferred embodiment by a bracket  25  which may be used to hold the radial arm  19  in a friction fit by forcing the bracket  25  against the radial arm  19  by turn screws  27   a  and  27   b , as would be well known to those skilled in the art. The invention is not limited to the brackets disclosed for a preferred embodiment for adjusting the arc of movement of the cutting blade  15  over the work support surface  13 , and as well known to those skilled in the art, any suitable bracket may be made for adjusting the length of the radial arm  19 , or for positioning the cutting blade  15  on the radial arm  19 , for adjusting the radius of the arc and the length of the arcuate path, made by the path of the cutting tool blade  15 , over a work surface  13 . As shown for a preferred embodiment, the cutting edge of the cutting tool  15 , shown in a preferred embodiment as a rotating cutting blade is in a plane formed by the cutting blade  15  and is orthogonal to the radial arm  19  and the radial arm direction or axis,  59 , as shown in  FIG. 3 .  
         [0036]     As shown for a preferred embodiment, in  FIG. 3 , the axis of rotation  16 , of shaft  21 , when fixed within bearing  23 , would be outside the work piece  12 , relative to its position under the cutting head comprising the support plate  31  supporting the cutting tool  15 , as would be understood by those skilled in the art. However, as would be apparent to those skilled in the art, the axis  16  could be over a work piece  12 , if suspended on a support anchored outside the work piece  12 .  
         [0037]     The motor  17  driving the cutting blade  15 , is shown mounted on a cutting head support plate  31 . An alignment plate  33 , is shown behind the cutting head support plate  31 . In a preferred embodiment, the cutting head support plate  31  is attached to the alignment plate by threaded screws  35   a  and  35   b , passing though alignment plate  31 , apertures  38   a  and  38   b , as shown in  FIGS. 2 and 3 , and held in a threaded apertures  77   a  and  77   b , as shown in  FIGS. 3 and 4 . The screws  35   a  and  35   b , may be turned to force the cutting head support plate  31  against the alignment plate  33 , to hold or clamp the cutting tool blade  15  in a precise indexed position relative to its distance to a work surface. As would be apparent to those skilled in the art, other suitable clamp means may be used to clamp or hold the support plate  31  in a fixed position relative to the alignment plate  33 .  
         [0038]     In a preferred embodiment, the cutting head support plate  31  may be mounted for rotating movement about screw  35   a  through aperture  38   a  and the axis of aperture  38   a , as shown in  FIG. 2  and serving as a pivot for movement of the cutting head support plate  31  through the arcuate path shown by arcuate slot  38   b , and in the arcuate indexing direction or path of arrow  40 . As shown for a preferred embodiment, screw  35   b  is inserted through the arcuate slot  38   b , to engage a mating threaded aperture  77   b  in alignment plate  33 , as shown in  FIG. 4 . The screw  35   b  passing through arcuate slot  38   b , may be used to clamp the support plate  31  in a position relative to the alignment plate  33  at a set position in said arcuate slot  38   b . As shown for a preferred embodiment, the arcuate slot  38   b  is opposed to aperture  38   a  and is in an arcuate indexing path of rotation relative to the axis of passing through aperture  77   a  in alignment plate  33  and aperture  38   a  in support plate  31 . As shown for a preferred embodiment, the arcuate slot  38   b , is in the radial direction from aperture  77   a . By indexing path or direction is meant the direction of movement of the cutting head support plate  31  and the cutting tool  15 , in the direction of the work piece  12 .  
         [0039]     The support plate  31  and cutting tool  15 , may be indexed in an indexing direction or path to the work piece  12 , on the work table  13 , by means of an indexing means shown in a preferred embodiment as comprising a threaded boss  39  positioned relative to the alignment plate  33  by pin  51  when inserted in aperture  53  or  56  in alignment plate  33 , and which is internally threaded. In a preferred embodiment, an indexing or positioning screw  41  engages the threaded boss  39  and has at its end a screw handle  43 . The opposite end of indexing screw  41  is mounted on cutting head support plate  31  to move the cutting head support plate  31  and the cutting tool  15 , about the axis of the screw  35   a  in and through the aperture  38   a , and through the arc described by the arcuate path of slot aperture  38   b , as the screw  41  is turned clockwise or counter clockwise.  
         [0040]     As shown and described for a preferred embodiment, the cutting head support plate  31  and the planar cutting tool or blade  15  may be progressively indexed in the indexing path in the plane of the cutting tool  15  and in the rotational or arcuate direction of the radial arm support  21  about the axis  16 , to move the cutting head blade, into deeper engagement with a work piece  12  and into the plane of the work piece, as shown in the schematic overhead representation of  FIG. 3 . By indexing movement is meant a continuous or step movement, of the cutting tool  15 , in the direction to the work piece  12 , as would be known to those skilled in the art. In the operation of the preferred embodiment, the indexing movement may be made between repeated arcuate movements of the cutting tool blade  15 , in the arcuate path  71   a ,  71   b , over the work piece  12 .  
         [0041]     In a preferred embodiment, as shown in a schematic view in  FIG. 2 , cutting head support plate  31  is shown with the rotary cutting blade  15  and the blade motor  17 , removed for the purpose of explanation. As shown in the schematic representation of  FIG. 2   a , the threaded boss  39  may be fixed in position relative to the alignment plate  33  by means of a positioning pin  51  positioned in the threaded boss  39 , and placed within support aperture  53  or  56 , within alignment plate  33 , in the direction of arrow  57 , as shown in  FIGS. 2   a  and  4 . The pin may be fastened in place by any suitable means known to those skilled in the art. Positioning pin  51  is used in cooperation with aperture  53  or  56  on alignment plate  33 , to position the boss  39  relative to the alignment plate  33  and to position the cutting head support plate  31  and the cutting tool  15 , relative to the alignment plate  33 .  
         [0042]     For a preferred embodiment, the support aperture  53 , may be mounted in an appendage or extension,  54  to plate  33  or within plate  33  as shown by support aperture  56 . The end of indexing screw  41  opposite the boss  39 , is attached to the cutting head support plate  31  by means of a boss  61  attached to the cutting head support plate  31 , through which the threaded screw  41  passes. Movement of the cutting head support plate about an axis through the aperture  38   a  and through the arcuate path of slot  38   b , in the arcuate path  40 , is by the interaction of bosses  63  and  65 , on boss  61  on indexing screw  41 . As would be apparent to one skilled in the art, as indexing screw  41  rotates, it moves in its axial direction  67  through threaded boss  39  moving boss  65  into contact with cutting heard support plate  31 , boss  61  and rotating the cutting head support plate  31  counter clockwise relative to the axis through aperture  38   a  and in the arcuate path direction  40  through the arcuate path slot  38   b . Similarly, as indexing screw is rotated in the opposite direction, it forces boss  63  into contact with cutting head support plate boss  61 , forcing cutting head support plate  31  to rotate clockwise about the axis through aperture  38   a  in the arcuate direction  40  and through the arcuate slot space  38   b , in the arcuate path  40 . As would be understood by those skilled in the art, the relative placement of boss  61  on plate  31  and placement of indexing screw  41  and threaded boss  39 , is shown for a preferred embodiment, schematically and for the purpose of explanation and the relative positions of the cooperative elements, as shown and described, for indexing the cutting head support plate  31  and the cutting too  15 , may be varied without departing from the disclosed inventive principles.  
         [0043]     In a preferred embodiment, the angle of the indexing screw  41  relative to the arcuate slot  40 , and aperture  38   a , is shown in the position of  FIG. 2 , for the purpose of explanation. As would be apparent to those skilled in the art, the angle of indexing screw  41  with respect to the axis of pin  51  through aperture  53  or  56 , could be varied in an angular position, to rotate the indexing screw  41  closer to the aperture  38   a , directing the force of the boss  61 , more directly on boss  63  and  65 , closer or more tangential to a desired point in the arcuate direction or path of rotation  40  of slot  38   b  about the axis described by aperture  38   a.    
         [0044]     Once the correct indexing position of the cutting tool  15  is reached for the progressive pass of the cutting head into the work piece  12 , in the arcuate path  71   a ,  71   b , as shown in  FIG. 3 , the cutting head support plate  31  may be fixed into position by use of a suitable clamp, shown in a preferred embodiment as set screws  35   a  and  35   b , passing through aperture  38   a  in the cutting head support plate  31  and into the threaded aperture  77   a  in the alignment plate  33  and through slot  38   b  in the cutting head support plate  31  and threaded aperture  77   b  in the alignment plate  33 , respectively, as shown in  FIG. 4 .  
         [0045]     As would be apparent to those skilled in the art, other suitable arrangements may be used for indexing the cutting head support plate  31  and the rotary cutting head  15  toward the work piece on the work support surface  13 , or for holding the support plate  31  and cutting head  15  in precise position relative to the work surface  13 , without departing from the disclosed inventive principles.  
         [0046]     Operation of the arcuate cutting tool is shown in the schematic representation of  FIG. 3 . As disclosed for a preferred embodiment, the cutting head comprising the support plate  31  and alignment plate  33 , and cutting tool  15  mounted on motor  17 , rotates about an axis  16  through in shaft  21 , in the arcuate direction  71   a ,  77   b , bringing the cutting tool  15 , into cutting contact with the work piece  12  to make an arcuate cut in the arcuate direction or path shown by  71   a ,  71   b.    
         [0047]     Indexing of the cutting tool or blade  15  in the indexing path direction of the work piece  12  to make successive cuts as is known for ceramic or stone materials, may be by the indexing screw  41  or by any other suitable step or continuous indexing arrangement as would be known to those skilled in the art.  
         [0048]     The side of the alignment plate  33  opposite to the side shown in  FIG. 1 , is shown in the schematic of  FIG. 4 . The alignment plate is shown detached from radial arm  19 , for purpose of explanation. The threaded apertures  77   a  and  77   b  for set screws  35   a  and  35   b  are shown in alignment plate with aperture  77   a , opposed to alignment aperture  53  for receiving alignment pin  51 , as shown in  FIG. 2   a.    
         [0049]     As may be seen from  FIG. 1 , for a preferred embodiment, when set screws  35   a  and  35   b  are screwed into the respective threaded apertures  77   a  and  77   b , the cutting head support plate  31  is forced against alignment plate  33  and clamped in the desired preset position for positioning the cutting tool  15  in an indexed position relative to the work piece  12 , as would be apparent to those skilled in the art.  
         [0050]     These and other features of the invention as disclosed invention may be varied in achieving the functions of a radial arm cutting tool for ceramic or other hard surfaces, with the plane of the cutting tool or cutting head perpendicular to the radial arm and mounted for arcuate movement relative to the axis of rotation of the radial arm.