Abstract:
A planer comprising: a body defining an exhaust aperture and including a wall, the wall defining a recess, a cutting drum rotatably mounted within the recess, a motor mounted within the body to rotatingly drive the cutting drum, the cutting action of the drum causing debris to be ejected from the recess; an airflow generator for producing an airflow within the body; a conduit defined within the body for directing the airflow, the conduit in communication with the exhaust aperture and connected to the recess for entraining and removing debris ejected from the recess; and a removable deflector having an inner end and an outer end, the deflector insertable through the exhaust aperture and connectable to the conduit for guiding the air flow and debris to outside of the body, and wherein the deflector is insertable at a downward slope from the outer end to the inner end.

Description:
The present invention relates to a planer and in particular to debris collection containers for a planer and airflow and chip removal in a planer. 
   BACKGROUND OF THE INVENTION 
   Planers comprise a body mounted on a shoe. A rotatable cutting drum is mounted within the body which is rotatingly driven by an electric motor also mounted within the body. An aperture is formed through the shoe through which part of the periphery of the cutting drum extends. Cutting blades are mounted on the drum which, as the drum rotates, periodically pass through the aperture and below the shoe. In use, the shoe is located on a work piece and the drum is rotatingly driven by the motor. When the blades pass through the aperture and move below the shoe, the blades engage with the workpiece and remove a thin slice of the workpiece from the surface of the workpiece, producing shavings or chips. Due to the rotational movement of the drum, the shavings or chips are thrown in a generally forward and upward direction in relation to the planer. One problem is the removal of the shavings or chips from the cutting area of the planer. A second problem is the collection of the shavings or chips for disposal. 
   In some designs of planer, the chips or shaving are directed using a deflector which directs the shavings or chips side ways from the planer. A fan or impeller mounted on the drive shaft of the motor can be used to generate an airflow which can be used to assist in the removal of the shavings or chips. DE19512262 discloses such a system. However, the problem with existing designs are that they are not efficient at mixing the air flow with the shavings or chips to entrain them for removal. 
   In order to collect the chips or shavings, a debris collection container is attached to the aperture through which the chips or shavings are ejected from the body of the planer. Existing designs of debris collection containers comprise a metal wire frame which is covered by a cloth bag such as a canvas bag. A tubular connector is attached to the metal wire frame and cloth bag and which can be attached to the ejection aperture so that the chips or shavings can pass through the connector from the planer to the debris collection container. A zipper is sewn into the side of the cloth bag which, when opened forms an aperture through which the shavings or chips can be emptied from the cloth bag. A problem with this design is that the hole formed by the unopened zipper is narrow making emptying the bag difficult. Furthermore, it is difficult for an operator to insert a hand into the bag to assist in the removal of the shavings or chips. The zipper can also scratch the hand of the operator. The shavings or chips can further interfere with the operation of the zipper. 
   BRIEF DESCRIPTION OF THE INVENTION 
   Accordingly there is provided a planer comprising a body comprising an aperture formed within it to accommodate a removable deflector, the aperture having at least one entrance;
         the body being mounted on a shoe, the shoe having an aperture formed through it;   a cutting drum rotatably mounted within a recess formed by a wall within the body, a part of the periphery of the cutting drum  6  projecting through the aperture in the shoe;   a motor mounted within the body to rotatingly drive the cutting drum;   at least one cutting blade mounted on the periphery of the drum capable of planing a work piece when the drum is rotating;   an airflow generator which creates an air flow when the planer is in use within the body for use for entraining debris created by the cutting action of the blade to assist in the removal of the debris;   directional means which, when the planer is in use, directs the airflow within the body towards the area where the cutting blade cuts a work piece in order to entrain the debris in the airflow within the body for removal from the body; and a removable deflector capable of being slid into the aperture by sliding the deflector through the entrance into the aperture for guiding the air flow and entrained debris from within the body to outside of the body when located within the aperture;   wherein the deflector slidingly locates within the body at a down ward slope from the edge of the body towards the centre of the body.       

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A number of embodiments of the invention will now be described with reference to the following drawings of which: 
       FIG. 1  shows a side view of the planer with the deflector removed; 
       FIG. 2  shows a side view of the planer of  FIG. 1  with the deflector inserted; 
       FIG. 3  shows the design of the deflector for use in the planer; 
       FIG. 4  shows a lengthwise vertical cross section of the planer of  FIG. 1  through the centre of the planer (excluding the motor and handle); 
       FIG. 5  shows a lengthwise vertical cross section taken through the planer of  FIG. 1  at the position indicated by dashed line Z in  FIG. 2  (excluding the handle); 
       FIG. 6  shows a perspective view of the first embodiment of a debris collection container; 
       FIG. 7  shows an exploded view of the debris collection container of  FIG. 6  excluding the cloth bag and circular end piece; 
       FIG. 8  shows a perspective view of the debris collection container of  FIG. 6  with the cap detached from the receptacle; 
       FIG. 9  shows a side view of the second embodiment of the debris collection container; 
       FIG. 10  shows a side view of the debris collection container of  FIG. 9  with the cap detached; 
       FIG. 11  shows a sketch of the connection mechanism of the debris collection container of  FIG. 9 ; 
       FIG. 12  shows a sketch of a top view of the planer of  FIG. 1  with the debris collection container of  FIG. 9  attached; 
       FIG. 13  shows a lengthwise vertical cross section of the second embodiment of the planer through the centre of the planer (excluding the motor and handle); 
       FIG. 14  shows a lengthwise vertical cross section taken through the planer of  FIG. 13  (excluding the handle); 
       FIG. 15  shows a downward side view of the planer of  FIG. 13  with the deflector inserted;  FIG. 16  shows a lengthwise vertical cross section taken through the third embodiment of the planer (excluding the handle); 
       FIG. 17  shows a vertical cross-section of the deflector located in a first position within the planer in accordance with the fourth embodiment of the planer; and 
       FIG. 18  shows a vertical cross-section of the deflector located within the planer in a second position in accordance with the fourth embodiment of the planer. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   A first embodiment of the planer will now be described with reference to  FIG. 1 to 5 . The planer comprises a body  2  having a handle  4  attached to the top of the body  2 . A cutting drum  6  is rotatingly mounted within a recess  50  in the body  2  of the planer. The body  2  of the planer is mounted on a shoe formed from two pieces  8 ,  10 . The rear part  8  is mounted rearwardly of the drum  6 . The forward part  10  is mounted forward of the drum  6 . An aperture  18  in the shoe is formed by the front  10  and rear sections of the shoe through which part of the periphery  20  of the cutting drum  6  extends. The height of the forward part  10  of the shoe can be adjusted in relation to the body  2  by the rotation of a knob  12  mounted on the front of the body  2  of the planer. The operation of the knob  12  is well known and will not therefore be discussed any further. 
   Mounted within cavity  14  of the body  2  of the planer is an electric motor  15  (shown schematically). The electric motor  15  rotatingly drives the cutting drum  6  via a drive belt (not shown). Cutting blades  16  are mounted within the cutting drum  6  and cut the workpiece upon which the planer is mounted as the cutting drum rotates. The cutting blades  16 , as the drum  6  rotates periodically pass through the aperture  18  and below the shoe to cut the workpiece in a well known manner. The construction of the electric motor  15 , the cutting drum  6 , the cutting blades  16  and the belt drive system are well known in the art and are therefore not discussed any further.
         Formed through the full width of the body  2  of the planar is a tubular exhaust aperture  24  having two entrances: first exhaust aperture  25  and second exhaust aperture  27 . A deflector  26  which is described in more detail below can be inserted into the aperture  24  from either side. This enables the shavings or chips to be directed to either side of the planar. A plastic (not shown) cap is used to seal the other aperture.   Referring to  FIG. 3 , the deflector  26  in accordance with the present invention is shown. The deflector  26  comprises two sections  28 ,  30 . The first outer section  28  is a tube of circular cross-section which, when the deflector  26  is inserted into the aperture  24  of the planer, projects outwardly from the body  2  of the planer shown in  FIG. 2 . The second section  30  is a curved section. The curved section has a substantially U shaped cross-section which forms a trough  31  which curves over its length. The sides  32  of the U-shaped curved trough  31  have been flattened as best seen in  FIGS. 4 and 5 . This results in a ridge  34  along the length of the curved section  30  where the flat surface  32  meets with a curved surface  36  of the U shaped cross section. The shape of the cross-section of the curved section  30  of the deflector  26  is such that it fits snugly into the aperture  24  in the side wall of the body  2  of the planer in order to hold the deflector  26  securely and preventing it from rotating within the aperture  24 . Formed between the two sections  28 ,  30  is an annular rib  38  which surrounds the circumference of the deflector  26 . The outer diameter of the annular rib  38  is greater than the diameter of the aperture  24  and thus prevents the deflector  26  from being inserted too far into the planer. When the deflector  24  is located within the body  2  of the planer, the rib  38  abuts against a side wall of the body  2  of a planer, the tubular section  28  remaining outside of the body. The rib is angled  35  in relation to the longitudinal axis  33  of the tubular section  28  so that it is less than ninety degrees as shown in  FIG. 3 . This is to allow the tubular section to point upwards when located within the body of the planer. The deflector  26  is formed as a one-piece construction and is made from plastic molded into the appropriate shape.       

   Mounted on the drive spindles of the motor  15  is a fan  39  (shown schematically) which generates an airflow. The air is directed into a cavity  40  formed in the body of the planer. The air then passes through a conduit  42  over the top wall  44  which forms the top wall of the aperture  24 . The direction of the airflow is indicated by Arrows W. The airflow is then directed downwardly to an area  46  in the body  2  forward of the wall  48  of the recess  50  in which the drum  6  is mounted. An expulsion aperture  52  is formed in the wall  48  of the recess  50  forward of the cutting drum  6  through which any debris created by the cutting action of the blades  16  would be thrown by the rotating blades  16 . The airflow W is directed within the body to a point  46 A below the expulsion aperture  52  in the wall of the recess and is directed to be blown across the aperture  52  within the body in a direction W having an acute angle to the direction of travel of any debris (shown by Arrow T) in order to entrain the debris in the airflow within the body. 
   The airflow W and entrained debris is directed upwardly until it engages with the underside of the curved section  30  of the deflector  26  which is located within the aperture  24  when the planer is in use. The airflow W and entrained debris is then directed out of the side of the planer through the tubular section  28  and into a debris collection container. 
   A second embodiment of the planer will now be described with reference to  FIGS. 13 to 15 . Where the same features are shown in second embodiment are the same as those in the first, the same reference numbers have been used. The second embodiment is exactly the same as the first embodiment except that the curved section  30  of the deflector forms the lower wall of the conduit  42  through which the airflow is directed over the deflector  26 . The aperture has no upper wall within the body  2  of the planer. 
   When the deflector  26  is located within the aperture  24 , the flat side walls  32  of the deflector  26  engage with internal walls  54  of the body and form an air tight seal preventing air which is passing over the deflector  26  from travelling between the flat walls  32  of the deflector and the internal wall  54  of the body ensuring it travels forward and downward to the point  46  below the expulsion aperture  52  for entraining of the debris. 
   Because the deflector  26  is angled downwardly by the angle  35  of the rib  38  being non perpendicular to the longitudinal axis  33  of the deflector, a large cavity is formed above the deflector  26  allowing air to easily pass over the top of the deflector  26 .  FIG. 15  shows a planer according to the second embodiment. The curve section  30  can be seen through the entrance of the aperture  24 . 
   A third embodiment of the planer will now be described with reference to  FIG. 16 . Where the same features are shown in third embodiment are the same as those in the first, the same reference numbers have been used. The third embodiment is exactly the same as the first embodiment except that a vent or nozzle  56  has been added within the body above the area  46  in the body  2  forward of the wall  48  of the recess  50  in which the drum  6  is mounted. The nozzle  56  directs air into the path of the air with entrained debris at an acute angle approximately at the same height as the top of the expulsion aperture  52  formed in the wall  48  of the recess  52  forward of the cutting drum  6  through which any debris created by the cutting action of the blades  16  would be thrown by the rotating blades  16 . It will be appreciated that the vent  56  can be located slightly lower down relative to the adjacent aperture  52 . 
   A fourth embodiment of the planer will now be described with reference to  FIGS. 17 and 18 . Where the same features are shown in the fourth embodiment are the same as those shown in the first embodiment, the same reference numbers have been used. The fourth embodiments is similar to the first embodiment except that a curved pivotal flap  200  is pivotally mounted within the aperture  24  where the deflector  26  is located. 
   The curved pivotal flap  200  is mounted about an axis  202  which extends in a vertical plane through the center of the width of the body  2  of the planer. The axis  202  is angled downwardly by a small amount relative to the horizontal so that the curved pivotal flap  200  pivots between an internal wall  206  of the body of the planer forming the top wall of the aperture  24  to the bottom side wall  208  of the entrance of the aperture  24 . The curved pivotal flap  200  extends from the axis of pivot  202  to the right side  204  of the body  2  of the planer as shown in  FIGS. 17 and 18 . The curved pivotal flap  200  is capable of pivoting from a position indicated by reference letter Q through the position indicated by reference letter R shown in dashed lines in  FIG. 17  to a position indicated by reference letter S also indicated in  FIG. 17  by dashed lines but shown as a solid line in. A spring  2 O 9  biases the curved pivotal flap to the lower position indicated by reference letter Q as shown in  FIG. 17 . 
   When the deflector  26  is not located within the planer, the curved pivotal flap  200  is biased to a downward position indicated by reference letter Q. When the flap  200  is located in this position, it forms an upper wall for right half of the aperture  24  as viewed in  FIG. 17  which is aligned with the upper wall  210  of the left hand side of the aperture  24  formed by the internal structure of the body  2  of the planer to produce a continuous curved upper surface of the aperture  24 . When the curved pivotal flap is in its downward position, it completely blocks the right hand entrance  212  to the aperture  24  from the chamber  214  where the air and entrained debris pass from the drum in order to be expelled. 
   When the deflector  26  is inserted into the aperture  24  from the left-hand side as shown in  FIG. 17 , the second section  30  of the deflector  26  is located adjacent the upper wall  210  of the left hand side of the aperture  24  formed by the internal structure of the body  2  and by the curved pivotal flap  200  on the right hand side of the aperture  24 . The insertion of the curved second section  30  of the deflector  26  causes no movement of the curved pivotal flap  200 . The shape of the curved pivotal flap  200 , both in cross-section and lengthwise, is such that it lies flush against the end part of the curved second section  30  of the deflector  26 . 
   When an operator tries to insert the deflector  26  from the right-hand side of the planer as shown in  FIGS. 17 and 18 , the curved section  30  of the deflector  26  is prevented from entering the aperture  24  by the curved pivotal flap  200  being located in its lower position indicated by reference letter Q due to the biasing force of the spring. In order for an operator to insert the deflector  26  into the aperture  24 , the operator pivots the curved pivotal flap  200  against the biasing force of the spring from the position indicated by reference letter Q to the position indicated by reference letter S as shown in  FIG. 18 . The operator can then insert the deflector  26  into the aperture  24 . When the curved second section  30  of the deflector  26  is located within the body  2  of the planer, the curved pivotal flap  200  is sandwiched between the internal wall of the body  2  of the planer and the second section  30  of the deflector, the shape of the curved pivotal flap  200  again being such that it lies flush against the curved second section of the deflector  26 . 
   A grip portion  216  is attached to the end of the curved pivotal flap  200  to enable the fingers of an operator to push the curved pivotal flap against biasing force of the spring. 
   The deflector  26  deflects the air and any entrained debris or chips either to the left when the deflector  26  is located from the left-hand side as shown in  FIG. 17  in the direction indicated by reference letter T or to the right when the deflector  26  is located from the right-hand side of the planer as shown in  FIG. 18  indicated by letter W. When the deflector is not inserted into the aperture  24 , the curved pivotal flap  200  is in its lowest position as indicated by reference letter Q, blocking the right hand entrance  212  of the aperture. As such, if the planer is operated without the deflector  26  inserted, the curved shape of the curved pivotal flap with the internal wall will direct the air and any entrained debris or chips towards the left enabling the planer to operate as if the deflector  26  was inserted into the left hand side of the body to of the planer. 
     FIGS. 6 to 8  show a first embodiment of a debris collection container which can be used with any of the four embodiments of planer previously described. The debris collection container comprises two sections, an end cap section  60  and the receptacle  70 . The end cap section  60  is manufactured in a one-piece construction from transparent plastic. The end cap section  60  comprises a tubular connection section  62  which connects to the first tubular section  28  of the deflector  26 . The tubular connection section  62  has a circular aperture (not shown) at one end whilst the other end meets with a dome shaped section or part spherical section  64 . The dome shaped section  64  comprises a rim  66  which surrounds a large aperture formed in the base of the dome shape section  64 . The rim  66  comprises an L-shaped slot  68  which forms part of a bayonet connection system for use in connecting the end cap section  60  to the receptacle  70 . Air and entrained debris pass through the aperture in the end of the tubular connection section  62 , through the tubular connection section  62  and into the dome shape section  64  before being expelled from the end cap section  60  through the large aperture in the base of the dome  64 . The shape of the dome is such that it acts as a deflector, bending the air and entrained debris through ninety degrees so that the air and entrained debris are travelling perpendicular to the direction they were travelling in when they were passing through the tubular connection section  62 . By constructing the dome shape section  64  in transparent plastic, the operator of the planer can look into the debris collection container to determine how full container is. Furthermore, as the planer is operating, the operator will be able to see the entrained debris passing through the tubular connection section  62  and pass through the dome section thereby enabling the operator to see that the planer is working correctly. 
   The receptacle  70  comprises a one end an annular plastic ring  72  which surrounds a large circular aperture which forms of the entrance to the receptacle  70 . The annular plastic ring  72  is divided lengthwise into two halves, a front half  74  having a diameter less than that of the in the diameter of the rim  66  of the dome shaped section  64  of the end cap section  60 , and a second rear half  76  having a diameter equal to that of the outer diameter of the rim of the dome shape section  64  of the end cap section  60 . A lip  78  is formed between the front and rear sections  74 ,  76  which abuts against the side of the rim of the dome shaped section  64  of the end cap section  60  when the end cap section is connected to the receptacle. Two pins  80  project radially outwardly from the surface of the front half. The pins are used as part of a bayonet connection to connect the end cap section to the receptacle by sliding into the L-shaped slot  68  formed in the rim  66  of the end cap section in connecting receptacle to the end cap section  60  in well known manner. 
   Located at the other end of the receptacle is a circular end piece  82  formed from plastic. The circular end piece forms a base of the receptacle and can be manufactured from transparent plastic material to enable an operator to view inside the receptacle from the base. The circular end piece  82  has a diameter which is the same as that of the annular plastic ring  72 . A helical spring  84  having the same diameter as that of the annular plastic ring  72  and the circular end piece  82  connects between the annular plastic ring  72  and the circular end piece  82  and holds the relative positions of the two parts. A tubular shaped cloth bag  86  connects between the plastic annular ring  72  and the circular end piece  82  and surrounds the helical spring. The spring acts to maintain the shape of the circular receptacle and to keep the circular cloth sheaf in shape. 
   Formed on the annular plastic ring is a plastic catch  88 . Formed on the circular end piece is a U-shaped plastic loop  90  which extends from that the circular end piece  82  towards the annular plastic ring  72 . The location of the U-shaped plastic loop  90  results in that when that the helical spring  84  is compressed by moving the circular end piece  82  towards the annular plastic ring  72 , the loop  90  engages with and attaches to the plastic catch  88 . This is ideal for storage. During use, the U-shaped plastic loop  90  is released from the catch and allows the helical spring  84  to bias the circular end piece  82  away from the annular plastic ring  72  to maximize the volume of space within the receptacle  70 . The helical spring maintains the shape of the receptacle the relative positions of the plastic annular is ring  72  and the circular end piece  82 . However, due to the resilient nature of the helical spring  84 , the structure allows some relative movements between the two enabling flexibility within the receptacle. However, when the receptacle is not in use, the helical spring  84  can be compressed so that the circular end piece  82  is moved towards the annular plastic ring  72  until the U-shaped plastic loop  90  engages with the plastic catch  88  to secure the circular end piece  82  to the annular ring  72  maintaining the helical spring  84  under compression and substantially reducing the volume of the space within the receptacle. This is ideal for storage purposes. 
   In use, the tubular connection section of the end cap is connected to the deflector  26  on the planer. The receptacle  70  is connected to the end cap section by use of the bayonet connector. The circular end piece  82  is disconnected from the catch  88  on the annular plastic ring  72  to allow the helical spring  84  to bias the circular end piece  82  away from the plastic annular ring  72  generating the shape of the container. 
   Referring to  FIGS. 9 to 11 , a second embodiment of the debris collection container is shown. The debris collection container comprises an end cap  100  and a receptacle  102  which is capable of being attached to the end cap  100 . The end cap  100  is manufactured in a one-piece construction from transparent plastic. The end cap  100  comprises a tubular connection section  104  which connects to the first outer section  28  of the deflector  26 . The tubular connection section  104  has a circular aperture at one end whilst the other end meets with a dome shaped or semi-spherical section  106 . The dome shape section  106  is mounted on a rectangular base  108  which comprises a rectangular rim  110  which surrounds a large aperture formed in the base of the dome shape section  106 . The rim  110  comprises a T-shaped slot  112  which forms part of a connection system for use in connecting the end cap  100  to the receptacle  102 . Air and entrained debris pass through the aperture in the end of the tubular connection section  104 , through the tubular connection section and into the dome shape section  106  before being expelled from the end cap  100  through the large aperture in the base  108  of the dome. The shape of the dome  106  is such that it acts as a deflector for the air and entrained debris and causes it to bend through ninety degrees so that the air and entrained debris are travelling perpendicular to the direction they were travelling in when they were passing through the tubular connection section  104 . By constructing the end cap  100  in transparent plastic, the operator of the planer can look into the debris collection container to determine how full the container is. Furthermore, as the planer is operating, the operator will be able to see the entrained debris passing through the tubular connection section and pass through the dome section thereby enabling the operator to see that the planer is working correctly. 
   The receptacle comprises a rectangular plastic frame  114  which acts as an entrance for the receptacle  102 . Attached to the rectangular plastic frame  114  is a large rectangular metal frame (not shown) made from stiff metal wire which forms of the structure of the receptacle. Attached to the rectangular plastic frame  114  and covering the large rectangular metal frame is a bag  116  made from cloth. The use of a cloth bag covering a metal frame is well know whether such will not be discussed any further. 
   Mounted within the rectangular plastic frame are two C shaped locking members  118  as shown in  FIG. 11  which are used to lock the receptacle  102  to the end cap  100 . The method of mounting is not shown. The two C shaped locking members  118  are mounted within the rectangular plastic frame  114  so that the ends  120  of each of the two arms of the C shaped locking members  118  face each other as shown in  FIG. 11 . Formed on the ends of the two arms of the two C shaped locking members  118  are pegs  122  which project outwardly. Helical springs  124  are mounted between the ends  120  of each pair of corresponding arms in order to bias the two C shaped locking members  118  outwardly away from each other as indicated by Arrows X. Rod s 126  is mounted within the helical springs to keep the helical springs  124  in position. Holes are formed within the rectangular plastic frame to enable the fingers of an operator to engage with the two C shaped locking members to push them towards each other against the biasing force of the springs  124 . 
   In order to attach the receptacle  102  to the end cap  100 , an operator would squeeze the two C shaped locking members  118  together against the biasing force of the springs  124  moving the pegs  122  formed on the ends  120  of the arms  118  of each of the two C shaped locking mechanisms  118  towards each other. Whilst held in this position, the pegs  122  are able to pass through the entrance of the T-shaped slot  112  in the end cap  100 . The operator can then the push the end cap  100  towards the receptacle  102 , the pegs  122  moving further into the T-shaped slot  112  until they become aligned with the top section of the T-shaped slot  112 . The operator then releases the C shaped locking members  118  to allow them to move outwardly due to the biasing force of the springs  124  causing the pegs  122  to travel outwardly in the top section of the T-shaped slot  112  thus locking the receptacle  102  to the end cap  100 . 
     FIG. 12  shows a view of the second embodiment of the debris collection container attached to the planer. As can be seen, the debris collection container is located along side the planer and the longitudinal axis  132  of the debris container extends in parallel to the longitudinal axis  130  of the planer.