Tile cutter

A tile cutter includes a cutting wheel, a motor which drives the wheel in use, and a main housing body and a worktop mounted on the main housing body to define a cutting surface upon which tiles may be supported when being cut. The main housing body includes a first compartment for housing the motor and a second compartment for housing the cutting wheel. The second compartment defines an open topped water compartment. The worktop has a main body fixedly secured to the main housing body and has an access opening closed by a movable access lid overlying the second compartment to close the open top of the water compartment. The access lid provides access to the water compartment. The worktop further includes one or more open topped drainage channels communicating with the cutting surface and the water compartment to permit, in use, water to drain from the cutting surface to the water compartment.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a tile cutter, and particularly, but not exclusively to a tile cutter for cutting ceramic tiles of the type used to cover walls and floors.

2. Related Art

It is known to cut tiles using a wheel which acts as a cutter in a similar way to a circular saw. The wheel is mounted in a housing on a spindle which allows the wheel to rotate about a substantially horizontal axis. The wheel is driven by a motor. The housing also houses the motor such that the motor is separate from the wheel. This is necessary because during operation of the wheel, water is directed onto the wheel in order to ensure that the tile is cut under wet conditions. Clearly it would be dangerous to allow the motor to come into contact with water.

It is necessary to ensure that the cutting wheel is wet during operation so that fragments of ceramic from the cut tile are removed from the vicinity of the wheel. In addition the water cools the wheel during operation to prevent it from overheating.

The known housing has an upper surface having a slot through which the wheel extends. A tile to be cut may be positioned appropriately on the surface, and then moved towards the rotating wheel to effect the cut.

Water directed onto the wheel collects on the surface of the housing. The surface of the housing comprises a drainage channel running around the periphery of the surface. In addition the surface may comprise ribbing which allows water to drain into the channel. Water then drains away from the housing via an outlet.

Known tile cutters of this type are made from metal, usually stainless steel. They are formed from sheet metal and it is necessary to weld the metal to form it into the required shape.

A problem with known tile cutters is that because they are formed from sheet metal, there are rough surfaces formed from the welding process. In addition, the upper surface including the drainage channel is formed with ribs which are necessary in order to strengthen the housing. Water draining from the housing during the cutting operation will contain fragments of ceramic from the tile being cut. These fragments of ceramic collect at the ribs and other rough surfaces of the housing making it difficult to clean the housing after use.

SUMMARY OF THE INVENTION

According to a first aspect of the present invention there is provided a tile cutter comprising a cutting wheel;a motor which drives the wheel in use;a main housing body and a worktop mounted on the main housing body to define a cutting surface upon which tiles may be supported when being cut;the main housing body comprising a first compartment for housing the motor; and a second compartment for housing the cutting wheel, the second compartment defining an open topped water compartment, the worktop having a main body fixedly secured to the main housing body and having an access opening closed by a movable access lid overlying the second compartment to close the open top of the water compartment, the access lid providing access to the water compartment, the worktop further including one or more open topped drainage channels communicating with the cutting surface and the water compartment to permit, in use, water to drain from the cutting surface to the water compartment.

According to a second aspect of the present invention there is provided a housing forming part of the tile cutter of the first aspect of the present invention.

By forming the first compartment separately from the other components of the tile cutter, the motor may be easily removed for maintenance purposes. In addition, if it is required to clean the other components after use, the motor may be detached from the remainder of the housing thus ensuring that the motor will not come into contact unnecessarily with water.

Advantageously, the cutting surface is formed from a die cast metal. This means that it may be moulded into any desired shape without having to use welding or other techniques which result in ribbing and rough surfaces being formed on the surface. The cutting surface may therefore comprise a drainage channel extending around the surface, and drainage ribbing running along the surface for directing water to the drainage channel.

Alternatively, the cutting surface may be made from a plastics material, and formed into the desired shape through injection moulding.

The tile cutter of the present invention thus has fewer, if any unnecessary protrusions or rough surfaces on the cutting surface. This results in more efficient drainage of water during use of the tile cutter. It is also easier to clean the housing after use.

In addition to housing the cutting wheel, the second compartment also contains water to be used during operation of the tile cutter. The compartment is filled with water prior to operating the tile cutter. During use, rotation of the cutting wheel causes water to cover the wheel and to be transferred to the cutting surface of the housing. The water then drains back into the compartment via the drainage channels of the housing and is thus recycled for further use.

Advantageously, the second compartment comprises an outlet formed in the base of the compartment, and a plug sealingly fittable in the outlet. During use, the plug forms a seal in the outlet, and water may be poured into the compartment for use during operation of the tile cutter. After use, water may be removed from the compartment by removing the plug from the outlet.

By means of the present invention, it is possible therefore to empty the compartment without having to tip up or overturn the housing. This results in a simpler and safer emptying procedure.

Preferably, the plug is in the form of an elongate member. When the plug is in place in the outlet, it extends from the outlet into the compartment. The plug comprises a bore extending along its length. This means that when the plug is in place, if water is poured into the compartment to a depth greater than the length of the plug extending from the outlet, water will drain out of the compartment via the bore. The plug is shaped such that the length of the plug extending from the outlet into the compartment ensures that it is not possible to overfill the compartment.

Advantageously, the cutting surface comprises a mitre portion which is moveable relative to the remainder of the cutting surface. The mitre portion may be moved to a position in which it lies substantially at an angle of 45 degrees to the remainder of the cutting surface. By lying a tile on the mitre surface it is possible to cut a mitre along an edge of the tile.

Conveniently, the tile cutter further comprises a guide bar extending across the cutting surface substantially parallel to the cutting wheel, and moveable along the cutting edge. The guide bar is used to position a tile appropriately relative to the cutting wheel to enable the tile to be cut along a predetermined line.

Once the guide bar has been moved to an appropriate position, it is clamped onto the cutting surface of the housing in order to prevent further movement of the guide bar. The tile to be cut is positioned so that one side of the tile abuts the guide bar. The tile is then moved towards the cutting wheel whilst keeping the one side of the tile in contact with the guide bar to ensure that a substantially rectilinear cut is produced.

Preferably, the housing comprises a channel formed in the underside of the housing which channel is shaped to receive a guide member.

This means that when the product is stacked at a wholesale or retail outlet, a first tile cutter may be placed on top of a second tile cutter such that the guide member of the second tile cutter is received within the channel of the first guide member.

This enables a stack of tile cutters to be formed and enables the product to be displayed without the need for packaging. This allows potential buyers to properly view and feel the product before buying.

Advantageously, the channel comprises studs extending from a first surface of the channel, and the guide member comprises corresponding bores positioned to receive the studs when a first tile cutter is stacked on top of a second tile cutter with the channel of the first tile cutter receiving the guide member of the second channel cutter. This allows a plurality of tile cutters to be securely stacked and easily removed from a stack if required.

The channel may be formed in either the first compartment or the second compartment.

Advantageously the tile cutter further comprises a wheel guard positioned over the wheel to prevent injury to a user from the wheel. The wheel guard additionally prevents water from splashing or spraying onto the user during use.

DETAILED DESCRIPTION

Referring toFIG. 1a tile cutter according to an embodiment of the present invention is designated generally by the reference numeral10. The tile cutter comprises a housing11comprising a first compartment12for housing a motor (as shown in FIG.9), and a second compartment13for housing the wheel cutter (shown in more detail in FIG.5). The second compartment13also defines an open topped water compartment for holding water which is required during the operation of the tile cutter.

Referring toFIGS. 4,5and9it will be seen that the housing11includes a main body MBto which a worktop WTis attached; the top WToverlying the entire top of the main body MB. The main body MBis preferably made from two body components, viz. a main body component MRand a minor body component MM. The minor body component MMdefines a lower half of the first compartment12and the remainder of the main body MBis defined by the main body component MR.FIG. 9shows the underside of the main body component MRand, as seen, component MRis preferably formed as a one-piece component which is preferably moulded from a plastics material. This is advantageous as it obviates the need to provide sealing joints between the dividing side walls between compartments12,13and provides a totally sealed top for the first compartment12. Minor component MM, when removed, provides easy access to the motor29. Preferably the component MMis a single piece plastics moulding. It will be seen fromFIGS. 2 and 9that the tile cutter further comprises a handle20which enables a user to conveniently carry the tile cutter10when the tile cutter is not required to be used. The handle20is formed from an upper portion21and a lower portion22. The upper portion21is formed as part of the main body component MRand the lower portion22is formed as part of the minor body component MM.

The worktop WTis secured to the main body MBto define the top of the tile cutter10. The upper surface of the worktop WTdefines a cutting surface14upon which tiles are placed for cutting.

The top WToverlies the water compartment defined by the second compartment13and so, in effect, defines a closure lid for the water component.

As seen inFIGS. 1,3and4, the worktop WThas a main body BMwhich is a single piece and which is preferably formed as a casting from a suitable metal or as a moulding from a suitable plastics material.

The main body BMincludes an integral open topped drainage channel15which extends about the periphery of the worktop WT. Preferably the drainage channel15extends about the entire periphery of the top WTalthough it is envisaged that it may extend partially around its periphery, e.g. along one or two sides only.

The main body BMalso includes a drainage outlet channel215which extends inwardly of the top WT. The outlet channel215communicates with drainage channel15and the water compartment to thereby enable water collected by channel15to drain into the water compartment.

To enable the channel215to extend inwardly without restricting the working area of cutting surface14and adversely affecting functioning of the top WTas a closure lid for the water compartment, the channel215has a closed top defined by a movable access lid24.

The lid24is located in an aperture124formed in the main body BMand is preferably cast or moulded from the same material as body BM. Raising of lid24provides access to the water compartment for filling with water and also cleaning.

The provision of the access lid24enables the main body BMof the worktop WTto be fixedly secured to the main body MBof the housing whilst providing access to an internally contained water compartment.

Preferably the access lid24is adapted to define a mitre guide for cutting mitres along an edge of a tile. This is achieved by hingedly connecting the lid24along side edge241such that the hinge axis is located closely spaced and parallel to the plane of the cutting wheel and providing the lid24with legs25for maintaining the lid24at a desired angle relative to the remainder of the cutting surface.

Preferably the desired angle is 45°. It is envisaged that the legs25may be adjustable such that the angle of the lid24relative to the cutting surface14may be adjusted to any desired angle.

Preferably the lid24is also provided with a flap26which defines a splash guard whilst the tile cutter is operated with the lid24in its raised position.

The tile cutter further comprises a guard17positioned over the wheel cutter18to prevent a user of the tile cutter10from being injured by the wheel cutter or from being sprayed or splashed by water.

The tile cutter10further comprises a guide member19which is movably attached to the worktop WT. When it is required to cut a tile having particular dimensions, a side of the tile is pushed into contact with the guide member, and the tile is then pushed forward into the cutting wheel18whilst maintaining close contact between the guide member19and the tile (not shown). This ensures that a substantially rectilinear cut is effected.

The guide member19is moved to an appropriate position such that when the tile to be cut is pressed against the guide member19, the cut will be positioned as required.

The guide member19may be clamped to the worktop WTby means of clamp36which when tightened onto housing11holds the guide member19in place. The clamp is tightened and released as appropriate using knob37.

The wheel guard17comprises an elongate portion23which serves to reduce the amount of water splashing or spraying in the direction of the user.

Turning now toFIG. 5, the cutting wheel18is shown in more detail. The cutting wheel is a conventional diamond cutter in which the cutting edge of the wheel is formed from a diamond matrix. The wheel18is mounted for rotation and is positioned within the second compartment13which also contains the water necessary during the operation of the tile cutter10. The wheel18is connected to a motor29(shown in more detail in FIG.9). As can be seen fromFIG. 9, the motor is contained within compartment12and is thus kept away from the water held within compartment13. It is only necessary to provide a shaft seal (not shown) where the motor shaft passess through the side wall13awhich separates compartments12,13in order to sealingly isolate compartments12,13.

Referring now toFIG. 5, an outlet28formed in the second compartment13is shown. The outlet28allows water to be removed from the housing11after use of the tile cutter10. During use of the tile cutter a plug28A in the form of an elongate plug is sealingly engaged with the outlet28. The plug28ahas a bore28brunning along its length and is chosen to have a length which is consistent with the dimensions of the second compartment13. If a user attempts to overfill the compartment with water, then excess water will drain from the compartment via the bore28bin the plug.

Referring now toFIGS. 6A and 6B, the wheel guard17is shown in more detail. The guard17comprises a portion31in which the elongate member is positionable. The guard has an end32which is slightly upturned in order to allow easy insertion of a tile into the guard in order to make contact with the wheel.

As shown more clearly inFIG. 8, the first compartment is formed with a channel33which channel comprises studs34. The purpose of the channel33will be described in more detail hereinbelow.

Referring now toFIG. 9, the motor29is shown in more detail.

Referring now toFIGS. 10to12, the channel33and the guide member19are described in more detail.

The channel33is formed such that its dimensions are substantially the same as the dimensions of the bar35forming the guide member19. When it is required to stack several file cutters for example at a wholesale or retail outlet, the guide member19is moved and positioned so that it is directly above the channel33. It is then clamped at this position by tightening clamp36on to the housing11using knob37. If it is required to stack a second file cutter10on the first file cutter then the channel33of the second file cutter will engage with the bar35on the guide member of the first channel cutter to enable two tile cutters to be stacked as shown inFIG. 11. Acolumn of several tile cutters may be formed in this way.

Referring toFIG. 12, it can be seen that the studs34are received within apertures30to ensure a stable stacking of the tile cutters10. However, when it is required to removed one file cutter from a second file cutter it is necessary merely to lift the first tile cutter away from the second tile cutter.