Abstract:
A machine for accurately cutting tiles, blocks of concrete, clay, blocks of stone and stone materials, wood and wooden materials is described. It may include a support stand which at its top supports a removable bed structure. The bed includes a motor-driven cutting disc recessed-mounted axially along pillow blocks such that a substantial portion of the cutting disc is projected above the bed surface and its mode of rotation is about a fixed centralized axis. Trolley track rails situated on distal ends of both long sides of the bed allow for lateral movement of the trolley above the bed surface to facilitate the cutting operation. During operation the object secured safely on the trolley which is manually moved towards the cutting disc while a perforated shower head sprays water onto the work piece. Water is filtered and recycled back to the shower via the bin situated below the cutting disc and then to the recycle and filter unit.

Description:
This application claims priority to provisional patent application No. 61/582,072 filed Dec. 30, 2011, which is hereby incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates in general to machines used in the accurate cutting of tiles of ceramic, porcelain, clay, marble, granite and composites and similar, blocks of wood, quarry tiles, blocks of concrete or clay, blocks of stone, stone materials, slates, conglomerates and similar by the effective use of a sliding trolley on a track or rails above a working table or bed secured upon a support structure. The movement of the trolley is to allow the work piece to engage the cutting tool or blade or disc where in this invention is fixed within the bed structure. It also relates to machines that can be easily transported or moved given their compact and modular construction. 
     2. Related Art 
     Conventionally, methods used for the accurate cutting of tiles, concrete blocks, clay bricks, blocks of wood and blocks of stone have never been consolidated into a singular machine, but rather, each machine with a unique object of processing. The cutting of these objects is ordinary within the construction industry where it can be found the intricate use of tiles of porcelain, clay, ceramic, marble, slate and granite each sometimes require unique and diverse cuts for specific sizing. These tiles are both functional and decorative in purpose where their application can be found in interior and exterior floors, walls, columns, counters tops, showers and baths of domestic and commercial buildings, roadways and walkways. Also, blocks of stone, concrete blocks and clay bricks are not all left without alteration requirements since proper building construction necessitates that these alterations be done since they are the principal materials in use. 
     In many conventional designs there exists in general two methods of engagement. First, a work piece is held fixed or fastened onto a bed surface while a cutting tool attached to a moving arm (pivoted at one end of the bed) is allowed to manually engage the work piece where all measures of control are exercised on the cutting tool. Or, second, a cutting tool is held fixed either above in suspension to the bed surface or partially recessed in the bed surface and the work-piece is made to manually engage the cutting tool either on a supported sliding table or unsupported, which by extension is of least accuracy. 
     BRIEF SUMMARY OF INVENTION 
     Accordingly, the limitations and problems as just described in the prior art are obviated according to the present invention as it relates in particular to a machine so designed that a working platform or bed is removably mounted onto a support stand or base with all degree of mobility on natural and man-made surfaces. The bed is disposed over a semi-projected motor driven cutting disc such that an appropriate portion of the disc is available above the bed surface for the cutting process. A trolley track allows manual movement of a trolley mounted on the track to achieve a successful cut. The trolley through its design facilitates the cutting process by securing the work piece using a block guide and providing a through-pass for the cutting disc to engage the work piece on the trolley along the inscribed cut line while the trolley is being moved in the direction of the cutting disc by means of a suitable handle. The rotation of the disc is typically in a direction towards the bed center at the end where the object advances to the cutting disc so as to prevent ground particulates dispersion to the air from the cutting process. 
     In the non-wood cutting process, a shower sprays water onto the work piece as a cutting aid and dust smother. Effluent water expended during cutting is channelled through a bin and collected in a recycle and filter unit where the water is filtered of entrained particulates by means of a series of filters and baffles and pumped back through the shower by means of a submersible pump, forming a closed-looped water circuit. This system is meritorious, novel and eliminates dust and water pollution associated with these processes since all is collected in the recycle and filter unit and the effluent water is not discharged into the work environment. 
     The modular design of the recycle and filter unit is a practical feature of embodiments of the present invention, incorporating a shower, water hoses and submersible water pump that collectively, can be utilized in conjunction with systems or machines requiring similar facilities during material cutting of similar type. A drain plug on one end of the unit can be removed to drain the unit through an outlet port; this, together with addition of fresh water, may keep the water turbidity within acceptable measure. A means is available to admit water directly to the shower via a connected water valve without use of the recycle and filter unit as in situations where the submersible water pump were to fail in operation due to electrical power failure or otherwise. 
     A bin positioned underside the bed serves as an intermediate accumulator and channel for the guided passage of effluent water from the bed surface and thence to the recycle and filter unit via a waste water hose. 
     The bin as just mentioned is quite unique both in function and design and presents an advantageous effect in the operational features of this machine. By virtue of its existence, there is no concern of water flooding onto or around work areas, neither uncontrolled wood cuttings nor sawdust left to the discretion of the wind, as the bin through its plural functions eliminates these common problems. It must be emphasized that such features are incorporated with the consideration of environmental preservation and cleanliness, which by extension makes for a comfortable work environment and increased worker safety. Such features are not likely seen in conventional machines. 
     The cutting of wood may be done in collaboration with a wood cutting table top locked onto the machine bed, where a blade slot ensures the cutting blade to be projected sufficiently above the wood cutting table top. A choice of wood cutting blade is discretionary owing to the inherent flexibility of operating modes. In such operation the wood is placed onto the wood cutting table top, a transparent wood cutting shield may be secured to the side of the machine bed and can be aligned and adjusted to provide suitable eye and operator protection. While the blade is in rotation, the wood piece is directed to the cutting blade in a manual fashion so as to cut the wood along inscribed cut lines in an effective and safe manner. The pieces are removed and the process may be repeated. Wood shavings produced during wood cutting operation are contained and directed where they can be easily disposed by disjoining a lower section of the bin to efficiently remove the wood cuttings to an appropriate containment for disposal. 
     Various means is provided to dismount the machine into several modular units comprising the wood cutting table top, trolley, wood cutting shield, bed with motor and blade arrangement, recycle and filter unit and the bin, where each modular unit may be fitted with handles for easy removal and mounting. The support stand may include both caster wheels for easy mobility and adjustable legs for stationary support. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       For a comprehensive exposure of the features, nature and advantageous effects of the present invention, reference is now made to the detailed description in conjunction with the associated drawings, in which: 
         FIG. 1  is an isometric view of an exemplary apparatus in accordance with an embodiment of the present invention. 
         FIG. 2A  is an isometric view of an exemplary apparatus including a mounted trolley in accordance with an embodiment of the present invention. 
         FIG. 2B  is another isometric view of an exemplary apparatus including a mounted trolley in accordance with an embodiment of the present invention. 
         FIG. 2C  is yet another view of an exemplary apparatus including a wood cutting table top and shield in accordance with an embodiment of the present invention. 
         FIG. 3  is an isometric view of an exemplary trolley apparatus in accordance with an embodiment of the present invention. 
         FIG. 4  an assembly drawing of an exemplary shaft apparatus including pillow block bearings, saucers, cutting disc and double pulley arrangement in accordance with an embodiment of the present invention. 
         FIGS. 5A and 5B  are isometric views of an exemplary bin apparatus and strainer, respectively, in accordance with an embodiment of the present invention. 
         FIG. 6  is an isometric illustration of an exemplary recycling and filter unit (partially exploded) including hoses, pump, power supply and cover. 
         FIG. 7  is an isometric view of an exemplary wood cutting table top in accordance with an embodiment of the present invention. 
         FIG. 8  is an illustration of a wood cutting shield assembly in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       FIG. 1  illustrates a block, stone, tile and wood cutting apparatus in accordance with an exemplary embodiment of the present invention. The apparatus comprises main support stand  1  which comprises adjustable legs  6  appended at the base that provide stability and lockable wheels  15  that provide means of mobility. Mountable upon support stand  1  is removable bed  2  upon which certain modes of operation are carried out. Handles  13  may be fitted, preferably each short side, to facilitate easy lifting and removing or mounting of bed  2  from or onto support stand  1 . 
     Bed  2 , much articulated by design, incorporates various features that allow for attachment to other elements of the machine. In accordance with a preferred embodiment and with reference to  FIGS. 2A ,  2 B and  2 C, frame motor support stand  21  is the attachment support for electrical motor  11  that drives cutting disc  10  via a belt-pulley arrangement. This configuration can provide safety by virtue of its location under bed  2  yet with an acceptable degree of accessibility to facilitate removal or service. Bed support stand  14  may be provided to ensure the independence of bed  2  when disjoined from the main support stand  1 ; as such, bed  2  can remain unaided without care of obliqueness when placed on a natural surface. Frame motor stand support  21  may include belt guard support bracket  20  that connects the belt guard  5  (see  FIG. 1 ) in place so as to provide a secure channel for belt movement throughout a straight path where the belt (not shown) engages a double pulley  34  of cutting disc assembly  68  (see  FIG. 4 ). With reference to  FIG. 4 , cutting disc shaft assembly  68  may include double pulley  34  fixed onto a shaft  33  which may be held in position by, e.g., pillow block bearings  35 . Pillow block bearings  35  may be supported by shaft support plate  19  (see  FIG. 1 ) to which the two pillow block bearings  35  are fastened. On an end of shaft  33  distal to bed&#39;s  2  interior may be a terminal point of double pulley  34  which is encompassed with the motor shaft (not shown) at the driver end via a drive belt (not shown). This configuration secures the passage and particularly isolates the belt from interference even by merit of its short loop distance. On an end of shaft  33  proximal to bed  2  interior is an access point where cutting disc  10  may be mounted onto shaft  33 ; disc  10  may be held fast into position on the shaft between two saucers  36 . Returning to FIGS.  1  and  2 A-C, access of cutting disc  10  is provided above the surface of bed  2  by means of an adequately sized opening  17  at an interior location of bed  2  thereby allowing the blade  10  to be sufficiently projected above the surface of bed  2 ; this provides an adequate means for engagement of a work piece with blade  10  during operation. 
     Bed  2  top surface may include a trolley track comprised of one or more rails  12 ; in a preferred embodiment, bed  2  includes two trolley track rails  12  in close proximity to either long outer edge that traverses linearly along the entire bed top surface. Trolley track rails  12  act as a conveyor for trolley  24  and a containment for water expended in the cutting process. Water expended during the cutting process may be contained by a circumscription formed by trolley track rails  12  on both ends and end stops  18  on the other two adjacent sides. The water contained is not confined indefinitely, but may be discharged through opening  17  into bin  3  of bin assembly  67  mounted at the underside. In one embodiment, bin  3  may be supported beneath bed  2  by means of wing flanges  8  inserted through bed slots  71  and secured with pins  72 . 
     With reference to  FIGS. 2A ,  2 B and  3 , in one exemplary mode of operation, trolley  24  is provided as a carriage operable to traverse bed  2 . End stops  18  may be provided on either or both extremes of bed  2 . Trolley  24  is configured to support a work piece to safely engage the cutting tool or disc  10  and provides a means to achieve a most accurate cut once set. The movement of trolley  24  may be facilitated by wheels  29 , for example, four small sheaves or grooved-edged metal wheels fitted onto sides of trolley  24  and adequately spaced apart that trolley  24  may roll on trolley tracks  12  on bed  2  unrestricted or without cause of derailment. To promote this movement, handle  28  may be outfitted at an end of trolley  24  as a means of moving and controlling the trolley  24  between both extremes of bed  2  in a very safe manner requiring no worker contact with the work piece. 
     In order for trolley  24  to slide over the projected cutting disc  10 , access-way  30  is provided throughout the flat horizontal surface  26  of trolley  24 , essentially dividing the flat horizontal surface into two sections which are kept apart and fixed by two supporting end-faces  22 . As such the access-way  30  is continued throughout these end faces  22  just short of its length providing sufficient clearance for the cutting disc to pass uninhibited. The two end-faces  22  are held fast and supported by means of a connecting arm  23  to the top of trolley  24 . A concrete block guide  32  may be placed on one side of the trolley&#39;s flat surface  26  and be used to keep the line of cut of the work-piece aligned to the cutting disc  10 ; this is accomplished by the concrete block guide  32  acting as a backing edge that prevents lateral movement of the work-piece on trolley work surface  26 . Easy adjusting and securing of the concrete block guide  32  may be provided by a fastening assembly. In one embodiment, the fastening assembly may comprise two adjustment-nuts  31  disposed to engage corner areas of concrete block guide  32 . With adjustment nuts  31  untightened, the concrete block guide  32  is free to move laterally across the trolley work surface  26  to the point of support to the work-piece. Concrete block guide  32  may then be secured in position by tightening both adjustment nuts  31 . The means provided within trolley  24  to accommodate movement over the blade  10  is effectuated during operation, as such; the operator may place the work-piece onto trolley work surface  26 , fixed and aligned using the concrete block guide  32 . In operation trolley  24  is manually moved on rails  12  to the other end of the bed  2  surface while the cutting disc  10  effectively passes through the access-way  30  of the trolley, engaging the work-piece. When trolley  24  reaches the other end of bed  2 , the cut would have been concluded where the work piece can then be removed and trolley  24  retracted to the start position. Trolley  24  design and function no longer require the hand of the operator to hold the work-piece to engage the cutting disc  10  as in many conventional machines. This minimizes the potential for unsafe conditions that can arise in operations of this nature. 
     In one embodiment, trolley  24  may comprise a water shower system including shower  25  which may span trolley  24  above trolley work surface  26 . In accordance with this embodiment, the water shower may provide a very effective medium in the removal of grit produced during cutting operation and to aid as a lubricant to the cutting disc  10  in the cutting of materials other than wood. Shower  25  may comprise a plurality of perforations in linear sequence and in such an arrangement to allow the water to spray onto the entirety of trolley work surface  26 . The water shower system may also include water valve  27 . In one embodiment, water valve  27  may be disposed below handle  28  of trolley  24 . Valve  27  may be used to admit water through shower  25  or to isolate water from shower  25  if water is not required. Water to shower  25  may be supplied through nozzle  69  by hose  52  connected to submersible pump  46  located within recycling and filter unit  4  (see  FIG. 6 ). Pump  46  may pump water through supply water hose  52  which may be held stable by means of water hose support  7  mounted onto a water hose support bracket at one side of bed  2  frame. During operation, the silt contained within the effluent water naturally flows through the access-way  30  on trolley  24  and through opening  17  in bed  2  and thus into bin assembly  67  where it is channelled to recycling and filter unit  4  and can return to shower  25  as filtered water. Non circulated water may be admitted directly to shower  25  via connection of a water supply hose to nozzle  69 , bypassing use of the recycle and filter unit  4  as in situations where submersible water pump  46  fails in operation due to electrical power failure or otherwise. 
     With reference to  FIGS. 5A and 5B , bin assembly  67  may be configured as an inverted pyramidal structure with a large open end connected under bed  2  surface in such a way as to follow-through from opening  17  in bed  2 ; the other end of bin assembly  67  is ported by means of waste water nozzle  37  and connects to recycling and filter unit  4  via water nozzle  37  and waste water hose  51  for transmission of waste water to same unit from bin assembly  67 . In the illustrated embodiment, the shape of bin  3  and bin assembly  67  may reduce the structural space required for the machine and can maintain the overall weight within acceptable limits. In the cutting of materials other than wood, a strainer  64 , for example a perforated steel sheet with handle  42 , may be inserted into bin assembly  67  in a horizontal orientation in order to restrict any entrained particulates within the discharged water. The bottom of bin assembly  67 , to which waste water nozzle  37  is attached, may be removed by detaching detachable bottom-section  41 . In one embodiment, detachable bottom-section  41  may be detachably attached by means of a tab, bolt and wing nut assembly (not shown) to the main part of the bin  3 . As such, in a wood cutting mode of operation, strainer  64  may not be required and all wood shavings produced during operation are contained and directed in bin assembly  67  which are easily removed when bin assembly  67  is filled by removing the bottom-section  41  and allowing the contents to fall into a disposable bag (not shown) or any similar disposal method or device. In addition, bin assembly  67  may be outfitted with one or more handles, e.g., handle  38 , for easy lifting and dismounting. 
     With reference to  FIG. 6 , recycling and filter unit  4  is so constructed to be modular in placement in relation to the machine. The said unit may be of rectangular form and reside at the base of the support stand  1  beneath bin assembly  67  where it can be easily removed by simply lifting and removing by the use of handle  43  on one end. Recycling and filter unit  4  may be closed by cover  65  with an appropriately sized inlet  48  that ports waste water hose  51  from bin assembly  67 ; handle  49  may be fitted at the top to accommodate removal of cover  65  and slot  47  may be extended from one end point of cover  65  to a suitable distance within cover  65  to permit the passage of supply water hose  52  and electrical power cable (not shown) to water pump  46 . 
     In one embodiment, recycling and filter unit  4  comprises a series of chambers in sequential order with the first chamber being the largest and right-most according to  FIG. 6 . Cover  50  may be sealed onto the top chamber to create a partial enclosure. Baffle plates  45  may be used to divide the recycling and filter unit  4  into the various chambers 
     Effluent water leaving the bin assembly  67  enters the first chamber via waste water hose  51 . The water accumulation rate in the first chamber is sufficient that through resident time, the larger of entrained sediments in the effluent water will settle at the bottom. On rising to the top of the chamber, water is filtered through an arrangement of perforations  73  at the top of the baffle plate on one end. This filter process through the baffle restricts entrainments too large to pass through and causes the water to accumulate within a second chamber which, being divided in two, causes water flow to a sub-chamber by means of an opening through the bottom of the baffle plate creating said division. This sub-chamber further filters the water by means of an appropriate voluminous filter such as a sponge (not shown) that utilizes entirely the available space. Water is transmitted to a third chamber by means of an arrangement of perforations  73  on the baffle plate on one end where it enters another sub-chamber and thence to a main chamber by overflowing across a short baffle plate. The water flow from this third chamber to the other two is by similar overflow means into the last chamber where water pump  46  may be disposed to circulate the filtered water. 
     Filtered waste water manifold  44  may be connected at the outside all chambers of the unit except the first; this manifold  44  allows recycling and filter unit  4  to be easily cleaned out and all chambers drained through said manifold  44  by removing an installed plug (not shown) at the end. 
     Outlet port  16  may be connected to the inlet chamber at the end of recycle and filter unit  4  to facilitate draining the unit  4  of any retained slush, sediments, water or to flush the unit  4  as required and to provide a means to relieve water from the unit  4  if there is no recycle water circuit due to an exclusion of water pump  46 ; in such case, it is adequate enough to admit non-circulated water through shower  25 , onto the work-piece, through the bin assembly  67 , through the first chamber of the recycle and filter unit  4  and thence through the outlet port  16  as with a natural water flow. 
     With reference to  FIGS. 2C and 7 , in one embodiment, the cutting of wood may be facilitated by the use of a wood cutting table top  63 . Wood cutting table top  63  may be a flat rectangular table with handles  53  located, e.g., centrally on both long sides, to provide lifting support for removal and mounting onto bed  2 . Wood cutting table top  63  may be held fast onto bed  2  by means of slotted plates  57 , configured to engage wood cutting table top lock nuts  9 , so as to lock the wood cutting table top  63  in place by tightening of wood table lock nuts  9 . The position of the wood cutting table top  63 , while mounted and held fast on the bed  2 , provides access to wood cutting disc  10  sufficiently projected through blade slot  70  to facilitate the appropriate cutting of wooden objects. Adjustable bar  58 , of appropriate height and width and of a length that spans the long side of the wood cutting table top  63  and in parallel relation to the cutting disc  10 , may be assembled onto the wood cutting table top  63  by means of supporting members that allow movement of adjustable bar  58  across wood cutting table top  63  up to a point where the finest cut of a wooden object would allow. As such, adjustable bar  58  serves as a guide and support in keeping a wooden object secured in position so as to maintain the cutting mark on the work-piece in-line with the cutting disc  10 , i.e., the line of cut. The supporting members within the constructs of the adjustable bar  58  may comprise nuts  54  that drive through adjustable stops  55  and into the end section of the adjustable bar  58 . The movement of nut  54  screw-in-wise forces adjustable stop  55  onto support  56  where by this action locks adjustable bar  58  in position; this construct may be on both end sides of adjustable bar  58  and provides an effective means to allow easy mobility and locking of adjustable bar  58 . Supports  56  may be configured to fit between track rails  12  such that wood cutting table top  63  is supported on bed  2  by track rails  12  and supports  56 . 
     With reference to  FIG. 8 , in association with the wood cutting table top  63  and the wood cutting process, wood cutting shield assembly  62  may be incorporated as an operator safety guard during the wood cutting operation. Wood cutting shield assembly  62  may comprise a transparent plastic sheet  66  (such as the brand PLEXIGLAS®) of a sufficient area disposed in bracket  59  and connected to arm  60 . The arm  60  may comprise hinge  61  at one end to optimize placement of sheet  66  about rotation A in accordance with the operator&#39;s position. Exemplary alternate positions are illustrated in dashed lines as sheet  66 -R 1  and  66 -R 2 . This action, with the combined effort of the horizontal, fully circular movement provided by the arm  60  when inserted in shield assembly mount pivot  40  (see  FIG. 2C ) about rotation B, enables the wood cutting shield assembly  62  to disposed in any position that may be required by the operator. Wood cutting shield assembly  62  allows the operator to clearly visualise the cutting process with the adequate eye and face protection that is needed to ensure the safety of the operator. It provides good impact strength to withstand the impact of deflected projectiles discharged during the wood cutting operation. 
     Adequate electrical power is supplied to an electric motor  11  to more than sufficiently drive the cutting disc  10  via the belt and pulley arrangement. An emergency stop button (not shown) is incorporated to safely switch off the motor when not in use and an adequate over-current protection device (not shown) is connected to the electric motor main supply to ensure protection of the electric motor and other auxiliaries. Submersible water pump  46 , housed within recycling and filter unit  4 , is powered from the electrical supply and is operated by means of a pump switch (not shown) independent of electric motor  11 . A light may be installed (not shown) to give indication of the pump  46  status of ON or OFF as operated.