Abstract:
An apparatus and method of using the same is disclosed. The apparatus has a base and a plurality of shears adjustably secured thereto. Each shear has one cutting element that is adjustable secured to the base and another cutting element that is pivotally secured to the other cutting element. A handle operably connects the cutting elements to allow simultaneous cutting by the shears. The cutting apparatus is useful in bending sheet material such as aluminum or vinyl coil stock used in trimming structures. In use, the shears are adjusted on the base to cut slits in desired locations on a sheet. A sheet is put in place, and the shears are actuated to cut a plurality of slits in a side of sheet material, preferably simultaneously. The sheet is then repositioned, and the shears are actuated to cut a plurality of slits in another side of the sheet. The sheet is then folded along lines extending between pairs of slits. The folded sheet is then affixed to a structure such as a house. The apparatus and method are particularly useful for site-forming trim from coil stock for use in areas such as fascia and soffits.

Description:
BACKGROUND OF THE INVENTION  
         [0001]    This invention relates to customized sheet work, and more particularly to an apparatus and method for site-forming sheet material, such as aluminum or vinyl coil stock.  
           [0002]    Siding material, such as aluminum or vinyl siding, is well known and can provide a low cost, low maintenance exterior to a home or structure. Whether in a new installation or in a re-siding job working, around trim such as fascia and soffits presents a number of challenges. It is often desirable to use sheet material such as coil stock, including aluminum coil stock, vinyl coil stock and the like, in areas such as the fascia and soffits. It is often desirable to site-form siding components for a variety of trim or eaves conditions. In such a situation, an installer will typically measure the relevant portions of a structure to determine where bends should be formed in the sheet material. The installer will then measure and mark opposite ends of the sheet material and will use shears, tin snips, or the like to individually cut slits at opposite sides of the sheet material. The slits are cut because it is typically easier to form a crisp, straight bend in sheet material if slits are cut in opposite sides of the sheet material, along a line at which the sheet will be bent. After the slits are cut, the installer will typically use a brake or bending tool to form the bends in the sheet material.  
           [0003]    The ability to site-form custom pieces offers a number of advantages. For example, it offers greater flexibility and a better fit and avoids delays and added costs when working with trim having non-standard dimensions. It may also reduce material transportation cost since it is typically easier to transport a roll of coil stock than it is to transport long pieces of pre-formed parts. It also makes it easier to provide joint free pieces covering longer spans. Still, site-forming of sheet material is not without problems. For example, it can be time-consuming to individually measure and mark places to be cut along multiple sides of sheet material. Similarly, it can be time-consuming to individually cut a number of slits in multiple sides of sheet material. Further still, it can be difficult to properly align and accurately cut multiple, uniform slits with the precision desired for forming straight, crisp bends or folds.  
         SUMMARY OF THE INVENTION  
         [0004]    It is therefore an object of the present invention to provide an apparatus that quickly, easily, and accurately cuts a plurality of slits in sheet material, along with a method of using the same.  
           [0005]    It is a still further object of the present invention to provide such an apparatus that may be quickly and easily adjusted to cut multiple slits in sheet material having a variety of spacings and patterns, along with a method of using the same.  
           [0006]    It is a further object of the present invention to provide an apparatus and method of using the same for cutting a number of slits in a side of sheet material simultaneously.  
           [0007]    It is a still further object of the present invention to provide an apparatus and method of using the same that quickly, easily, and repeatedly provides consistent, uniform, accurate, and precise slits.  
           [0008]    It is a still further object of the present invention to provide an apparatus and method of using the same that provides for consistent displacement of corresponding portions of corresponding slits in opposite sides of sheet material.  
           [0009]    It is a still further object of the present invention to provide an apparatus and method of using the same that allows a cutting element to be rotated clockwise or counterclockwise as desired to provide the cutting action.  
           [0010]    It is a still further object of the present invention to provide an apparatus useful in bending sheet material and a method of using the same that provides for simultaneously cutting a plurality of slits along one side of a sheet, then simultaneously cutting a plurality of slits along another side of the sheet.  
           [0011]    It is a still further object of the present invention to provide an apparatus useful in trimming with coil stock and a method of using the same that provides for simultaneously cutting a plurality of slits along one side of a sheet, then simultaneously cutting a plurality of slits along another side of the sheet.  
           [0012]    It is a still further object of the present invention to provide an apparatus useful in customized sheet preparation and a method of using the same that provides for using a plurality of shears that are adjustable along a length of a base.  
           [0013]    Toward the fulfillment of these and other objects and advantages, an apparatus and method of using the same are disclosed. The apparatus has a base and a plurality of shears adjustably secured thereto. Each shear has one cutting element that is adjustably secured to the base and another cutting element that is pivotally secured to the other cutting element. A handle operably connects the cutting elements to allow simultaneous cutting by the shears. The cutting apparatus is useful in bending sheet material such as aluminum or vinyl coil stock used in trimming structures. In use, the shears are adjusted on the base to cut slits in desired locations on a sheet. A sheet is put in place, and the shears are actuated to cut a plurality of slits in a side of sheet material preferably simultaneously. The sheet is then repositioned, and the shears are actuated to cut a plurality of slits in another side of the sheet. The sheet is then folded along lines extending between pairs of slits. The folded sheet is then affixed to a structure such as a house. The apparatus and method are particularly useful for site-forming trim from coil stock for use in areas such as fascia and soffits. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    The above brief description, as well as further objects, features and advantages of the present invention will be more fully appreciated by reference to the following detailed description of the presently preferred but nonetheless illustrative embodiments in accordance with the present invention when taken in conjunction with the accompanying drawings, wherein:  
         [0015]    [0015]FIG. 1 is a front elevation view of a cutting apparatus for use in the present invention;  
         [0016]    [0016]FIG. 2 is a partial, rear view of a cutting apparatus for use in the present invention;  
         [0017]    [0017]FIG. 3 is an enlarged side view of a pair of cutting elements;  
         [0018]    [0018]FIG. 4 is a side elevation view of a structure with a site-formed sheet affixed thereto;  
         [0019]    [0019]FIG. 5 is a front elevation view of a cutting apparatus with a sheet in place for cutting; and  
         [0020]    [0020]FIG. 6 is a partial elevation view of a sheet having slits cut according to the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0021]    Referring to FIG. 1, the reference numeral  10  refers in general to a cutting apparatus of the present invention. The apparatus  10  comprises a base  12  and a plurality of shears  14  adjustably secured thereto.  
         [0022]    The base  12  has a long, substantially planar lower member  16 , and end members  18  and  20  extending upward therefrom. The base  12  may be made from any number of different materials or different combinations thereof, but it is preferably made from a strong lightweight metal, such as aluminum. In the preferred embodiment, the lower member  16  is formed from an aluminum plate and is ¾″ thick, 16″ long, and 4″ wide. The end members  18  and  20  are also formed from aluminum plates that are ¾″ thick and 4″ tall. At one end of the lower member  16 , the end member  18  is aligned with a front face of the lower member  16  and extends 2¾″ rearward over most of its height. A hole  22  passes through the width of the end member  18  at a low, front portion thereof. A lower limit member  24  is formed integrally with the end member  18  and extends 1¼″ rearward thereof so that a rear face of the lower limit member  24  is aligned with a rear face of the lower member  16 . The lower limit member  24  extends ¾″ above the lower member  16 . An upper limit member  26  is affixed to the top of the end member. The upper limit member  26  is ¾″ thick, ¾″ wide, and 4″ long. A notch is formed in a lower, rear portion of the upper limit member  26  so that a rear portion of the upper limit member  26  is ½″ thick, ¾″ wide, and 1¼″ long. The rear face of the upper limit member  26  is aligned with the rear face of the lower member  16 . The lower member  16 , end member  18 , and upper limit member  26  are rigidly affixed to one another, such as using screws.  
         [0023]    At the other end of the lower member  16 , end member  20  is provided. The end member  20  extends 3″ forward from the front face of the lower member  16  and extends 2¾″ rearward over most of its height. The portion  28  extending forward of the front face of the lower member  16  is used as a stop to assist in aligning sheet material  30 . The front face of the lower member  16 , the elongate member, or portions of the base  12  in close proximity thereto may be provided with markings or other indicia  32  showing measurements in units such as inches or centimeters. The markings  32  are preferably aligned to begin at and measure distance from the inner face of the stop portion  28  of end member  20 . A hole  22  passes through the width of the end member  20  above and rearward of the front face of the lower member  16 . A lower limit member  24  is formed integrally with the end member  20  and extends 1¼″ rearward thereof so that a rear face of the lower limit member  24  is aligned with a rear face of the lower member  16 . The lower limit member  24  extends ¾″ above the lower member  16 . An upper limit member  26  is affixed to the top of the end member  20 . A hole  34  may be provided in an upper surface of the end member  20  to receive a tool  36  such as a hex wrench that may be useful in making adjustments in the apparatus  10 . The upper limit member  26  is ¾″ thick, ¾″ wide, and 4″ long. A notch is formed in a lower, rear portion of the upper limit member  26  so that a rear portion of the upper limit member  26  is ½″ thick, ¾″ wide, and  1¼″ long. The rear face of the upper limit member 26 is aligned with the rear face of the lower member 16. The lower member 16, end member 20, and upper limit member 26 are rigidly affixed to one another, such as using screws. It is understood that the upper and lower limit members 26 and 24 may take any number of different shapes, sizes, and configurations. It is also understood that the upper and lower limit members 26 and 24 may be adjustable to control the length of slits to be cut.    
         [0024]    An elongate member  38 , such as an aluminum rod having a ½″ diameter, is secured between the end members  18  and  20  and extends lengthwise along the base  12  above and rearward of the front face of the lower member  16 , extending substantially parallel with the front face of the lower member  16 . The elongate member  38  passes through holes  22  and is held in place between the end members  18  and  20  by fasteners  40  such as nuts, bolts, screws, or the like. It is preferred that the elongate member  38  be easily removable to facilitate adding or removing additional shears  14  depending upon the number of slits desired. It is of course understood that the elongate member  38  may take any number of shapes, sizes, and lengths. For example, the elongate member  38  may have a square or rectangular cross-section. It is also understood that the elongate member  38  may be secured to the base  12  in any number of ways or formed integrally therewith. It is of course understood that the base  12  may be formed from any number of different materials and that any or all of the components of the base  12  may be formed integrally or in any number of different combinations. It is also understood that the base  12  may take any number of different sizes, shapes, and configurations.  
         [0025]    Each shear  14  is preferably substantially identical, so only one shear will be described in detail. The shear  14  has a mounting block  42 , a first cutting element  44  rigidly secured to the mounting block  42 , and a second cutting element  46  pivotally secured to the first cutting element  44 . The mounting block  42  is preferably aluminum that is 1″ wide, 3″ tall, and 2″ long. A notch  48  is formed in an upper portion of the block  42 .. The notch is ¼″ wide and 1″ tall and extends over the entire length of the block  42 . A hole  50  passes through the width of the block  42  at a lower, central portion thereof. The elongate member  38  passes through the hole  50 , and the block  42  rests on the upper surface of the lower member  16 . The front face of the block  42  extends ½″ forward of the front face of the lower member  16 , and the length of the block  42  extends substantially perpendicular to the elongate member  38  and to the front face of the lower member  16 . Another hole  52  passes from the rear face of the block  42 , lengthwise through block  42  to the hole  50 . This hole  52  is preferably threaded, and a threaded member  54 , such as a bolt or other form of set screw is in threaded engagement therewith. Additional, holes may be provided through the width of the block  42  in an upper portion thereof for securing the first cutting element  44  to the block  42 .  
         [0026]    The cutting elements  44  and  46  are preferably made from a metal such as steel. It is preferred that the cutting elements  44  and  46  be made from a metal other than aluminum to provide for greater stiffness or hardness. The first cutting element  44  is ¼″ thick, 1″ tall, and 3″ long. The rear face of the first cutting element  44  is aligned with the rear face of the block  42 , and the front face of the first cutting element  44  extends 1″ forward from the front face of the block  42  and 1.5″ forward from the front face of the lower member  16 . The length of the first cutting element  44  extends substantially perpendicular to the length of the elongate member  38  and to the front face of the lower member  16 , and the front face of the first cutting element  44  extends substantially parallel to the front face of the block  42  and to the front face of the lower member  16 . Holes are provided in a rear portion of the first cutting element  44  for rigidly affixing the first cutting element  44  to the block  42 . A hole is provided forward of the front face of the block  42  for pivotal attachment of the second cutting element  46 . A generally V-shaped notch  56  is formed in the front face of the first cutting element  44 . The notch  56  is ⅜″ tall at the front face of the first cutting element  44  and extends ⅜″ rearward along the length and across the entire width. The upper and lower faces of the notch  56  are substantially flat or planar.  
         [0027]    The second cutting element  46  is ¼″ thick, 1″ tall, and 5½″ long. When the second cutting element  46  is in a neutral position the front face of the second cutting element  46  is aligned with the front face of the first cutting element  44 , the top face of the second cutting element  46  is aligned with the top face of the first cutting element  44 , and the rear face of the second cutting element  46  is aligned with the rear face of the lower member  16 . A hole  58  passes through the width of a distal portion of the second cutting element  46  for receiving a handle  60 . Another hole is provided forward of the front face of the block  42  for pivotal attachment of the second cutting element  46  to the first cutting element  44 . A generally V-shaped notch  62  is formed in the front face of the second cutting element  46 . The notch  62  is ⅜″ tall at the front face of the second cutting element  44  and extends ⅜″ rearward along the length and across the entire width. As best seen in FIG. 3, the upper and lower faces of the notch  62  are slightly curved or convex.  
         [0028]    The handle  60  operably connects a plurality of shears  14 . The handle  60  is an elongate member such as a rod having a ½″ diameter and a length of 21″. The handle  60  passes through holes  58  in the distal portions of the second cutting elements  46  of the shears  14 . The handle  60  extends substantially parallel with the front and rear faces of the lower member  16  over the length of the base  12  and is preferably long enough to allow a user to grasp both ends of the handle  60  outside of the location at which the handle  60  passes between the upper and lower limit members  26  and  24  at both ends of the base  12 . The ends of the handle  60  may be knurled for easier gripping. It is of course understood that the handle  60  may be made from any number of different materials and may take any number of shapes, sizes, and configurations. For example the cross section of the handle  60  may be square or rectangular, and appropriately shaped holes may be provided in the second cutting element  46  for a keyed fit. The handle  60  may also be rigidly secured to one or more of the second cutting elements  46 . Similarly, threaded members  64 , such as set screws, or other means may be used to releasably secure the handle  60  to one or more of the second cutting elements  46 . For ease of adjustment, it is preferred that the handle  60  be slidable through most if not all of the holes  58  of the second cutting elements  46 .  
         [0029]    In operation, sheet material  30 , a brake or bending tool, and the cutting apparatus  10  of the present invention are provided to a work site having a structure  66  to which the sheet material  30  is to be affixed. The sheet material  30  is preferably coil stock, such as aluminum or vinyl coil stock, and is more preferably painted aluminum coil stock. Measurements are taken of the relevant portions of the structure  66  to determine desired locations for bends in coil stock to be affixed to the structure  66 , such to cover fascia or soffit areas. For example, as best seen in FIG. 4, it may be desirable to site-form coil stock to form or cover eaves fascia  68  and to form or provide support for a soffit panel  70 . A structure  66  may have eaves trim  72  affixed to or adjacent roof sheathing  74 . Utility trim  76  may be affixed to the top of the eaves trim  72 , and an F-channel  78  may be affixed to the bottom of the eaves trim  72 . To site-form a piece of coil stock to serve as an eaves fascia  68 , one might want to form one bend  80  in an upper portion of the coil stock so that the piece may be hung from the utility trim  76 . Similarly, one might want to form two or more bends  82  and  84  in a lower portion of the coil stock so that the piece may be clipped over the F-channel  78 .  
         [0030]    After the relevant measurements are taken to determine the desired locations for bends in the coil stock, the shears  14  are positioned to slit the coil stock in the desired locations. To adjust the positioning of a shear  14 , a user loosens the set screw  54 , slides the shear  14  along elongate member  38  to the desired location, and tightens the set screw  54  to inhibit movement of the block  42  relative to the base  12 . Markings  52  assist in determining the desired location of the shear  14 . If a user wishes to adjust the length of the slits to be cut, the upper and lower limit members  26  and  24  may be adjusted to arrest upward and downward motion of the handle  60  at a desired location. Shears  14  may be added to or removed from the base  12  depending upon the number of bends desired. To add or remove shears  14 , the fastener  40  securing the elongate member  38  to one of the end members  18  or  20  is removed, and the elongate member  38  is slid from the hole  22 . One or more shears  14  may be added or removed, and the elongate member  38  secured back in place between the end members  18  and  20 .  
         [0031]    Coil stock is unrolled and cut to provide a sheet of material  30  of the desired length and width. The cutting elements  44  and  46  are placed in a neutral position in which the upper faces of the cutting elements  44  and  46  are substantially parallel. As best seen in FIG. 5, the sheet  30  is positioned for cutting, with one side  88  of the sheet  30  abutting and flush with the stop portion  28  of the end member  20  and another side  90  of the sheet  30  in position within the notches  56  and  62  of the shears  14 , abutting the back portions of the notches  56  and  62 . With the sheet  30  in position, a user moves the handle  60  upward or downward until the handle  60  strikes the upper or lower limit members  26  or  24 . The shears  14  simultaneously cut a first plurality of slits  92  (FIG. 6) in the side  90  of the sheet  30 . As best seen in FIG. 6, the slits  92  are substantially uniform. For each, the slits  92  are substantially parallel with one another and have substantially the same length. Each slit  92  extends substantially perpendicular to side  90  and substantially parallel to the side  88 . The front edge  94  of each slit  92  is displaced slightly downward from the rear edge of the slit  92 .  
         [0032]    The user removes the sheet  30  and flips it over so that the surface  96  of the sheet  30  that originally faced upward now faces downward. The user positions the sheet  30  for cutting with one side  88  abutting and flush with the stop portion  28 . This is the opposite end of the same side  88  that abutted the stop portion  28  for the first cutting. Another side  98  of the sheet  30  is placed in position within the notches  56  and  62  of the shears  14 . Side  98  is the side opposite and parallel to side  90 . With the sheet  30  again in place, the user moves the handle  60  in the opposite direction until the handle  60  strikes the lower limit members  24  or upper limit members  26  to simultaneously cut a second plurality of slits  100  in side  98  of the sheet  30 . For example, if the user rotated the handle  60  upward or counterclockwise to cut the first plurality of slits  92 , the user would rotate the handle  60  downward or clockwise to cut the second plurality of slits  100 , or vice versa. The slits  100  are substantially uniform with each other and with slits  92 . For example, the slits  100  are substantially parallel with one another and have substantially the same length. Each slit  100  extends substantially perpendicular to side  98  and substantially parallel to the side  88 . When surface  96  faces upward, the front edge  102  of each slit  100  is displaced slightly downward from the rear face of the slit  100 . Each slit  92  aligns with a corresponding slit  100  so that a line  104  extending between corresponding slits  92  and  100  extends over the length of the sheet  30 , substantially parallel to side  88  and substantially perpendicular to sides  90  and  98 . Cutting the slits  92  and  100  so that the front edges  94  and  102  of corresponding pairs of slits  92  and  100  are displaced in the same direction or so that the rear faces of corresponding pairs of slits are displaced in the same direction provides for improved bending. For example, it reduces the risk of paint scratching, chipping or flaking during and after bending, and it reduces the risk of bends, buckles, or indentations in the bend. It is of course understood that the slits  92  and  100  need not be cut in opposite sides of the sheet  30 . It is also understood that the slits  92  and  100  may be aligned in any number of different ways and may have any number of different lengths. It is also understood that the sheet  30  need not be flipped over between cuttings and that the handle  60  need not be moved in opposite directions to form the first and second plurality of slits  92  and  100 . Similarly, it is understood that the handle  60  need not be displaceable or rotatable in both upward and downward directions.  
         [0033]    After the first and second plurality of slits  92  and  100  are cut, the sheet  30  is removed from the cutting apparatus  10 , and the brake or bending tool is used to form bends  80 ,  82 , and  84  in the sheet  30  along lines  104  extending between corresponding slits  92  and  100  to site-form the sheet  30 . After the bent sheet  30  is site-formed in this manner, it is affixed to the structure  66 , such as by nailing or clipping it into place onto the structure  66  or onto utility trim  76  affixed to the structure  66 . Although it is preferred that the bent sheet  30  be site-formed, it is understood that the cutting apparatus  10  may be used at a work site or remotely therefrom. Similarly, it is understood that the sheet material  30  may be bent at a work site or remotely therefrom.  
         [0034]    Other modifications, changes, and substitutions are intended in the foregoing, and in some instances, some features of the invention will be employed without a corresponding use of other features. For example, the first cutting element  44  may be attached directly to the elongate member  38  or to the base  12 . Similarly, the elongate member  38  need not be used to affix the shear  14  to the base  12 . The base  12  may take any number of shapes, sizes, and configurations and may, for example, also serve as a base or part of a brake or bending tool. The shears  14  may take any number of shapes, sizes, and configurations. For example, the shears  14  need not have corresponding first and second cutting elements that are pivotally secured to one another. If used, the first and second cutting elements need not have corresponding notches  56  and  62  for cutting. It is also understood that the shears  14  may form slits  92  and  100  of any number of different shapes, sizes, and configurations. The cutting apparatus  10  may be formed from any of a wide variety of materials, and different parts of the cutting apparatus  10  may be formed from the same or different combinations of materials. Portions of the cutting apparatus  10  may for example be formed using metals, plastics, ceramics, woods, resins, or any number or combinations of materials. It is understood that all measurements and quantitative information are given by way of example only and are not intended to limit the scope of the invention. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.