Abstract:
A plane such as a shoulder plane having at least two set screws positioned in apertures in the body, the set screws adapted to bear against opposite sides of the blade laterally to adjust the blade in position. An adjustment assembly is also provided, where rotation of a knob adjusts longitudinal movement of a traveler component, and laterally pivoting the knob allows lateral movement of the blade to the extent permitted by the set screws. A knob for rotational readjustment of the handle is also provided.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims priority to U.S. Provisional Patent Application Ser. No. 60/494,316 filed Aug. 11, 2003 entitled “Shoulder Plane,” which is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION  
       [0002]     This invention relates to shoulder planes and rebate or rabbet planes used in woodworking.  
       BACKGROUND  
       [0003]     Planes generally include an adjustable blade and are used in woodworking to flatten and smooth a surface. Conventional planes use blades oriented at an angle (generally between about 12° and 45°) to the sole of the plane and, therefore, to the surface being worked.  
         [0004]     When using a shoulder plane and cutting into a corner, it is critical to position the blade with the adjacent edge exactly parallel with or projecting slightly from the body on the working side. Traditional shoulder planes require a manual trial and error process to achieve optimal positioning. In addition, shoulder planes are, by nature, very difficult to hold and to manipulate, since no features can permanently project to either side of the body of the plane since one plane side usually registers against a workpiece during use.  
         [0005]     Therefore, it would be beneficial to have a shoulder plane that is more easily handled and that has a blade that is more easily positioned.  
       SUMMARY  
       [0006]     An improved shoulder or rabbet plane according to embodiments of this invention includes at least two set screws positioned in apertures in the body, the set screws adapted to bear against opposite sides of the blade laterally to adjust the blade position. An adjustment assembly allows rotation of a knob in order to adjust longitudinal movement of a traveler component that, in turn, controls blade projection, and lateral pivoting of the knob to allow lateral movement of the blade to the extent permitted by the set screws. A lever cap knob is repositionable. The lever cap knob is received in a channel and may be secured in any selected position along the channel by tightening the knob. The lever cap knob may be repositioned by loosening the knob and retightening it in another position along the channel. Therefore, the handle may be loosened, rotated and secured in a desired position. Alternatively, the lever cap knob may be removed from the plane entirely. In an alternative embodiment, a bullnose shoulder plane includes at least two set screws adapted to bear against opposite sides of the blade laterally to adjust the blade in position. The bullnose shoulder plane may be converted to a chisel plane by removal of the toe piece.  
         [0007]     Thus, this shoulder plane improves on such conventional planes by providing structure for easily, accurately and reproducibly establishing the lateral position of the cutting blade and by providing a knob for handling the plane in use that may be positioned to project from a wide variety of positions, including on either side of the plane while not obstructing needed contact between the plane and a workpiece or fence. Holes in the plane body sides further facilitate manipulation of the plane in use.  
         [0008]     It is therefore one feature of this invention to provide a shoulder plane having a blade that is adjustable laterally.  
         [0009]     A further feature of this invention is a shoulder plane having an adjustment assembly for adjusting longitudinal movement of the blade.  
         [0010]     Another feature of this invention is a lever cap knob that may be rotated and secured in a desired position.  
         [0011]     Yet another feature of this invention is a bullnose shoulder plane having a blade that is adjustable laterally and that is convertible to a chisel plane by removing the toe piece of the plane.  
         [0012]     Yet another feature of this invention is a bullnose shoulder plane having a pocket adapted to receive a digit of a user of the plane. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0013]      FIG. 1  is a perspective view of a first embodiment of the shoulder plane of this invention.  
         [0014]      FIG. 2  is a top view of a portion of the body and the blade of the shoulder plane shown in  FIG. 1 , showing the relationship between the blade, the setscrews, and the sides of the plane body.  
         [0015]      FIG. 3  is a perspective view of the shoulder plane shown in  FIG. 1 , showing the movement of the variable position knob.  
         [0016]      FIG. 4  is an exploded perspective view of the shoulder plane shown in  FIG. 1 .  
         [0017]      FIG. 5  is a perspective view of an alternative bullnose embodiment of the shoulder plane of this invention.  
         [0018]      FIG. 6  is an exploded perspective view of the plane of  FIG. 5 .  
         [0019]      FIG. 7  is a side view in partial cross section of the plane of  FIG. 5 . 
     
    
     DETAILED DESCRIPTION  
       [0020]     As may be seen by reference to  FIGS. 1-4 , the shoulder plane  20  of this invention includes generally a body  22 , a toe  24  and a lever cap  26 . A brace  30  (see  FIG. 3 ) is positioned between sides  28  of body  22 . Handle apertures  32  in each side  28  of body  22  facilitate holding and manipulating the shoulder plane  20  during use.  
         [0021]     Pin aperture  34  (visible in  FIG. 3 ) on the top face of toe  24  receives dowel pin  36 . The opposite end of pin  36  is captured in an annular depression  38  of toe adjustment screw  38 , so that turning toe adjustment screw  40  in and out acts on dowel pin  36  to force toe  24  in or out. Screw aperture  42  on the top face of toe  24  receives toe locking screw  44 , which passes through bore  46  in the top of the body  22  and into the screw aperture  42  on toe  24 , securing toe  24  to body  22 . Toe locking screw  44  may be loosened so that adjustments may be made to toe  24  by adjusting toe adjustment screw  40 .  
         [0022]     Cutting edge  48  of blade  50  is positioned between the toe  24  and body  22  at the sole or bottom surface of the shoulder plane  20 . Cutting end  52  of blade  50  includes top surface  54  against which forward end  56  of lever cap  26  presses. Four adjustment setscrews  58  positioned in apertures  59  in body  22  to bear against opposite sides  51 ,  53  of blade  50 , two on each side of the blade, are used to move the blade  50  laterally within body  22 . After the setscrews  58  have been set, the setscrews  58  act as stops or locators that enable the blade  50  to quickly be re-set into position after removal for sharpening.  
         [0023]     Adjustment assembly  60  includes traveler  62 , which is located near the end of shaft  64  proximal to adjustment pivot  66  and opposite adjustment knob  68 . Traveler  62  includes pin  70 , which is received in one of pin holes  72  of arm  74  of blade  50 . Shaft  64  is threaded through pivot  66  that is stationary within a bore in body  22 . Rotating shaft  64  using knob  68  therefore causes traveler  62  to move longitudinally within body  22 . Laterally pivoting knob  68  causes blade  50  to move laterally to the extent permitted by setscrews  58 .  
         [0024]     Lever cap rod  76  includes threaded end  78  which is received in threaded opening (not visible) in lever cap  26 . The opposite end  80  of the rod  76  is smooth, with a knurled wheel  82  positioned between the two ends. End  80  of rod  76  bears against blade  50 , and rotating wheel  82  exerts force separating the lever cap  26  and blade  50  to lock both in the body  22 .  
         [0025]     Lever cap  26  secures the blade  50  in position. Rear end  84  of lever cap  26  includes a smooth, generally flat palm surface  86  that may be used as a handle. An additional, adjustable handle is provided by lever cap knob  90 . Knob  90  is positioned on a shaft  92  that extends through a slot or channel  88  in the lever cap  26  and is threaded into a lever cap pin  96  positioned in a bore  98  transverse to the slot  88 . The knob shaft  92  of the lever cap knob  90  is received in the shaft hole  94  of the lever cap pin  96 . Forcing lever cap pin  96  into pin housing  98  compresses o-ring  100 , which provides resistance to rotation of cap pin  96 , thereby maintaining a position of knob  90  to which pin  96  is rotated. Pin  96  includes slot  102 , which divides pin  96  into two legs  104 . Threaded hole  94  does not extend into the second of the legs  104 . Rotating knob  90  screws knob shaft  92  into hole  94  and against the second of the legs  104 , forcing the legs  104  of pin  96  apart, thereby locking the pin  96  in position within frog  26 .  
         [0026]     Lever cap knob  90  may be secured in any selected position along channel  88  by tightening knob  90  and repositioned by loosening the knob  90  and retightening in another position along the channel  88 . As may be seen by reference to  FIG. 3 , lever cap knob  90  thus provides a handle that can be loosened, rotated and secured in the desired position, which is typically away from the working face. Lever cap knob  90  may also be removed from the plane entirely when there is no usable position for it.  
         [0027]     The body  22  and toe  24  may be made from ductile cast iron, or any other suitable material. The blade  50  may be made from A2 tool steel or any other suitable material. The toe locking screw  44  and the toe adjustment screw  40  may be made from stainless steel, or any other suitable material. The lever cap  26  may be made from zinc aluminum alloy (ZA12), or any other suitable material. The lever cap knob  90 , pin  96  and adjustment knob  68  may all be made from brass or any other suitable material. The shaft  64 , pivot  66  and traveler  62  of the adjustment assembly  60  may be formed from steel, or any other suitable material. While the shape of knob  90  shown is one that functions well, other shapes could also be utilized.  
         [0028]      FIGS. 5-7  illustrate an alternative embodiment, a bullnose shoulder plane  110 . Bullnose shoulder plane  10  will perform as either a bullnose or a chisel plane, as required. In one embodiment, shown in  FIG. 5 , the toe locking knob  112  may be loosened to remove the toe piece  114  for chisel plane configuration, allowing use up to a blind corner. The toe piece  114  may be replaced by sliding the toe piece onto the body  116  and under the toe locking knob  112  until it stops at the previously set mouth opening position, which is controlled by set screw  117  that contacts body  116  at contact point  119 . The adjustable toe provides the ability to narrow the mouth  118  for very fine shavings with minimum tear-out.  
         [0029]     This bullnose embodiment is shaped to fit comfortably in the user&#39;s hand. The low, broad lever cap  120  is adapted to be received in the palm of the hand, and the forefinger rests in the toe pocket  122 , providing improved control and enhancing ease of use. One benefit of this embodiment is that removal of the toe piece  114  does not affect the handling of the device, as only the toe piece  114  is removed, rather than any other part of the plane, such as the broad lever cap  120 .  
         [0030]     As described above with reference to  FIGS. 1-4 , set screws  124  in bullnose plane  110  provide accurate positioning of the blade and allow replacement after sharpening without lateral adjustment.  
         [0031]     A bullnose shoulder plane according to this invention can measure 4{fraction ( 3 / 4 )}″ long by 1″ wide and weigh just over 1{fraction ( 1 / 4 )} lb, but other sizes and weights are possible. In the embodiment described in the preceding sentence, the blade may be ⅛″ (0.125″) thick and made of A2 tool steel hardened to Rc60-62. The body and toe of the bullnose shoulder plane may be formed from ductile cast iron and machined and ground so that the sole and sides are flat and square, allowing the plane to be used on its side.  
         [0032]     In the shoulder plane of this invention, a low bed angle of 15° may be combined with a 25° blade bevel, resulting in a cutting angle of 40°.  
         [0033]     As will be appreciated by those skilled in the art, this invention can be practiced in numerous alternative embodiments in addition to those shown in the drawings and described above without departing from the spirit of this invention or the scope of the following claims.