DEVICE FOR CUTTING SHEETROCK

Abstract

A device for cutting a substrate including a frame with a first cutting mechanism operatively connected to the frame. The first cutting mechanism is slidable in a first direction relative to the frame. The device further includes a second cutting mechanism operatively connected to the frame, which is slidable in the first direction as well as slidable in a second direction relative to the frame. The second direction is substantially perpendicular to the first direction. The first and second cutting mechanisms are adjustable to select a desired cut depth and a thickness of a substrate such that the frame may be moved along an edge of the substrate to remove excess material from the substrate.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 60/895159, filed on Mar. 16, 2007, which is hereby incorporated by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a device for cutting sheetrock or similar material. More particularly, the present invention relates to a device for cutting sheetrock wherein the device may be adjusted vertically and horizontally so that a piece of sheetrock may be cut at a desired location by sliding the device across the edge of the sheetrock.

BACKGROUND OF THE INVENTION

Traditional methods for cutting sheetrock are difficult, time-consuming, and prone to error. First, the person cutting the sheetrock has to measure the location to be cut at several points so that an accurate and straight cut can be made. Then, the cut needs to be made. Any error in measurement or cutting renders the sheetrock unusable, which increases costs.

SUMMARY OF THE INVENTION

An object of the present invention is to provide a device for cutting sheetrock.

An additional object of the present invention is to provide a device for cutting sheetrock that creates more accurate cuts and is less time-consuming than traditional methods.

It is yet another object of the present invention to provide a device for cutting sheetrock that creates accurate cuts and saves time through the use a device that may be adjusted vertically and horizontally.

It is an additional object of the present invention to provide a device for cutting sheetrock that may be slid across an edge of a piece of sheetrock to remove the edge.

An embodiment of the inventive device includes a frame with a first cutting mechanism operatively connected to the frame. The first cutting mechanism is slidable in a first direction relative to the frame. The device further includes a second cutting mechanism operatively connected to the frame, which is slidable in the first direction as well as slidable in a second direction relative to the frame. The second direction is substantially perpendicular to the first direction. The first and second cutting mechanisms are adjustable to select a desired cut depth and a thickness of a substrate such that the frame may be moved along an edge of the substrate to remove excess material from the substrate.

These and other objects of the present invention will be better understood in view of the Figures and preferred embodiment described.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a device for cutting sheetrock according to an embodiment of the present invention.

FIG. 2 is a partially sectioned, perspective view of a device for cutting sheetrock, according to another embodiment of the present invention.

FIG. 3 is an exploded view of the device for cutting sheetrock shown in FIG. 1.

FIG. 4 is an exploded view of the device for cutting sheetrock shown in FIG. 2.

FIG. 5 is a perspective view of an ergonomic handle usable with the embodiments of FIGS. 1 and 2.

FIG. 6 is a front view of a panel of sheetrock placed within the devices of FIGS. 1 and 2.

DETAILED DESCRIPTION OF EMBODIMENTS

FIG. 1 shows one embodiment of the present invention, a device 10 for cutting sheetrock. The device 10 includes a substantially U-shaped frame 12 having a bridge portion 14 and parallel arms 16 that extend horizontally from the bridge portion 14. An adjustable post 18 and a movable post assembly 19 are assembled to the frame 12.

The bridge portion 14 defines an rectangular opening 13 for receiving the adjusting post 18. The bridge portion 14 also includes a threaded aperture or hole 20 (best shown in FIG. 3) extending from an inner surface or face of the opening outward to an outer surface of the bridge portion 14.

Each of the parallel arms 16 has a horizontal ridge 22. In one embodiment, each horizontal ridge 22 extends from the bridge portion 14 to a free end of the corresponding parallel arm 16. Each of the parallel arms 16 has a slot 24 coincident with the horizontal protrusion or ridge 22. Each slot 24 is marked with measurements for indicating a horizontal distance of the movable post assembly 19 from the adjusting post 18.

When received in the opening of the bridge portion 14, the adjusting post 18 is slidably movable perpendicular to the parallel arms 16. The adjusting post 18 carries a first blade 26 and is marked with measurements to indicate the vertical position of the first blade 26 relative to the parallel arms 16. The adjusting post 18 includes a vertical adjuster 28 for securely positioning the first blade 26 relative to the frame 12, so that the first blade 26 will score or cut the sheetrock at a first desired position. Preferably, as shown in FIGS. 1 and 2, the first blade 26 is rotatably mounted to the post 18 by a screw or similar threaded fastener. Optimally, the cutting edge of the first blade 26 protrudes from the adjusting post 18 about one-sixteenth of an inch ( 1/16″), as best shown in FIG. 1. Alternatively, the first blade 26 may be fixedly mounted to the post 18, or may be formed integral with the post 18.

In a simple embodiment of the vertical adjuster 28, the hole 20 is a threaded hole and the threaded post of the dial 34 is movable toward and away from the adjusting post 18 by rotation of the threaded post in the threaded hole 20, thereby clamping or releasing the adjusting post 18 for vertical sliding motion within the opening 13 of the bridge portion 14.

In another embodiment, the vertical adjuster 28 includes a vertical T-grooved slot (not shown), a nut housed in the slot and slidably movable along the slot, and the vertical-adjust dial 34 having a threaded post extending through the hole 20 of the bridge portion 14. When the adjusting post 18 is received between the parallel arms 16, the T-grooved slot is aligned with the hole 20 and the threaded post of the vertical-adjust dial 34 accordingly cooperates with the threads of the nut to clamp the adjusting post 18 against the bridge portion 14 of the frame 12 by action of the nut in the slot. Thus, when the vertical-adjust dial 34 is operated to clamp the adjusting post 18, the first blade 26 is securely positioned relative to the parallel arms 16. When the vertical-adjust dial 34 is operated to release the adjusting post 18, the first blade 26 is slidably vertically movable perpendicular to the parallel arms 16.

In yet another embodiment, the vertical adjuster 28 includes a toothed rack (not shown) that is slidably movable within the adjusting post 18, and that is securely positioned by meshing of the teeth with a splined shaft of the vertical-adjust dial 34. When the adjusting post 18 is received between the parallel arms 16, the toothed rack is vertically movable perpendicular to the parallel arms 16. The first blade 26 is fixedly mounted on an end of the toothed rack protruding from the adjusting post 18, for example by a screw, by adhesive, or by integral forming of the first blade 26 on the toothed rack. Accordingly, the first blade 26 is vertically adjusted perpendicular to the parallel arms 16 by operation of the dial 34.

Referring now to FIGS. 1 and 3, the movable post assembly 19 carries a second blade 38 for scoring the sheetrock at a second desired position on a face of the sheetrock opposite the first desired position. The second blade 38 is rotatably mounted to the movable post assembly 19. The movable post assembly 19 also has two horizontal grooves 40 for engaging with the corresponding horizontal ridges 22 of the parallel arms 16. The movable post assembly 19 includes a horizontal and vertical positioner 42 for vertically and horizontally positioning the second blade 38 relative to the frame 12. Like the adjusting post 18, the movable post assembly 19 is marked with measurements indicating a vertical position of the second blade 38 perpendicular to the parallel arms 16. A horizontal distance between the adjusting post 18 and the movable post assembly 19 along the parallel arms 16, as indicated by the measurements marked along the slot 24, corresponds to a thickness of the sheetrock to be scored or cut using the device 10.

The movable post assembly 19 further includes a rectilinear frame 62 having two outer faces 48 in which are formed the horizontal grooves 40 for mating with the horizontal ridges 22. The frame 62 also has inner faces 50 opposed to the outer faces 48, inner faces 64 substantially perpendicular to the inner faces 50, and outer faces 65 opposed to the inner faces 64. A hole 54 extends from one of the horizontal grooves 40 to the corresponding inner face 50, and a hole 55 extends from one of the outer faces 65 to the corresponding inner face 64. Vertical faces 56 and 66 of the central block 46 abut and slide against the inner faces 50 and 64. Again, the second blade 26 is mounted to the central block 46.

The horizontal and vertical positioner 42, as shown in FIGS. 1 and 3, includes the dial 68 mounted on a threaded shaft 74 that extends through the slot 24 to cooperate with threads of the hole 54 in the frame 62 for drawing the frame 62 toward the parallel arm 16a, thereby clamping the frame 62 to prevent motion along the parallel arms 16. The horizontal and vertical positioner 42 also includes a dial 76 having a threaded shaft 77 that cooperates with threads of the hole 55 in the frame 62 for clamping the central block 46 against motion perpendicular to the parallel arms 16.

Thus, the horizontal and vertical positioner 42 is operable to prevent motion of the movable post assembly 19 and of the second blade 26 relative to the frame 12. In another version of the horizontal and vertical positioner 42, a vertical groove is formed in one of the vertical faces 66 of the central block that is disposed closest to the parallel arm 16a. The vertical groove has a T-section and the horizontal and vertical positioner 42 includes a nut captured and slidably movable within the vertical T-groove. When the dial 68 is operated to tighten the horizontal and vertical positioner 42, the central block 46 is drawn toward the parallel arm 16a by action of the nut in the T-groove, thereby clamping the frame 62 and securely positioning the movable post assembly 19 and the second blade 26 relative to the frame 12. When the dial 68 is operated to loosen the horizontal and vertical positioner 42, the central block 46 is released to slide vertically within the frame 62, and the frame 62 is released to slide horizontally along the ridges 22, thereby permitting the second blade 26 to be positioned relative to the frame 12.

In an alternative embodiment shown in FIGS. 2 and 4, the movable post assembly 19 includes two slides 44 and a central block 46 to which the second blade 38 is mounted. Each of the slides 44 has an outer face 48 abutting one of the parallel arms 16, on which the horizontal groove 40 is formed, and an inner face 50 abutting the central block 46, on which a vertical ridge 52 is formed. A slotted through-hole 54, as best shown in FIG. 4, is formed in each slide 44 extending from the horizontal groove 40 to the vertical ridge 52. The central block 46 has two opposing faces 56 abutting the two slides 44. In each opposing face 56 is formed a vertical groove 58 that slidably mates with the corresponding vertical ridge 52. A vertical slot 60 extends through the central block 46 perpendicular to the opposing faces 56, and is aligned with the holes 54 when the central block 46 is assembled to the slides 44.

The horizontal and vertical positioner 42, as shown in FIGS. 2 and 4, includes a dial 68 mounted on a threaded shaft 70 that extends through the slots 24 of the parallel arms 16, through the vertical slot 60 of the central block 46, and through the slotted holes 54 of the slides 44 to cooperate with a clamping means 72 associated with the parallel arm 16b. In a simple version of the first embodiment, the clamping means 72 is a nut slidably abutting on a surface of the arm 16b opposed to the horizontal ridge 22 of the arm 16b.

When the dial 68 is operated to tighten the clamping means 72, the two parallel arms 16 are drawn together to clamp therebetween the slides 44 and the central block 46, thereby securing the movable post assembly 19 and the second blade 26 relative to the frame 12. Loosening the horizontal and vertical positioner 42 enables the slides 44 to be moved horizontally along the ridges 22 and enables the central block 46 to be moved vertically along the grooves 52, thereby permitting the second blade 26 to be positioned relative to the frame 12.

Optionally, each of the parallel arms 16 can have a removable pin 80 set into a hole formed on the horizontal ridge near the free end of the arm 16, so that post assembly 19 cannot slide out of frame 12 even if the horizontal and vertical positioner 42 accidentally is removed from the slot 24.

Many materials, including wood, thermoplastic, and metal, are suitable for making the frame 12, the adjusting post 18, and the various parts of the movable post assembly 19. The adjuster 28 and the positioner 42 should be made from a sturdy material durable for frequent operation. The first and second blades 26, 38 should be made from a tough and hard material suitable for scoring sheetrock and suitable for holding an edge. Hard woods such as oak, hard thermoplastics such as polycarbonate or polyvinyl chloride, and many various metals are suitable for making the first and second blades 26, 38.

FIG. 4 shows an ergonomic handle 82. The handle 82 can be mounted to the frame 12 by various means. In one embodiment, the handle 82 comprises a base portion 84 and a grip portion 86, and is mounted to the frame 12 by screws 88 inserted through holes formed in the base portion 84. Although the handle can be made of various materials, it is preferred that the base portion 84 be formed of a sturdy material such as metal or hard plastic, and that the grip portion 86 comprise a cushioning material such as rubber or thermoplastic foam.

In operation, an edge of a sheetrock panel is placed in between the adjustable post 18 and movable post assembly 19 such that the panel edge 104 abuts the underside of the parallel arms 16a, 16b. The adjuster 28 and the positioner 42 are operated to position the first and second blades 26, 38 at a desired cut depth 100 (indicated on the vertical measurement marks of the posts 18 and 19) and at a thickness of the panel 102 (indicated on the horizontal measurement marks of the parallel arms 16). The device 10 is then dragged along the edge in a smooth motion. The first and second blades 26, 38 drag along opposing faces of the panel, thereby scoring or cutting the panel at the desired cut depth.

While the invention has been described with reference to the preferred embodiments, it will be understood by those skilled in the art that various obvious changes may be made, and equivalents may be substituted for elements thereof, without departing from the essential scope of the present invention. Therefore, it is intended that the invention not be limited to the particular embodiments disclosed.

Claims

1. A device for cutting a substrate, said device comprising:

a frame;

a first cutting mechanism operatively connected to said frame, said first cutting mechanism being slidable in a first direction relative to said frame;

a second cutting mechanism operatively connected to said frame, said second cutting mechanism being slidable in said first direction as well as slidable in a second direction relative to said frame, wherein said second direction is substantially perpendicular to said first direction; and

wherein said first and second cutting mechanisms are adjustable to select a desired cut depth and a thickness of a substrate such that said frame may be moved along an edge of said substrate to remove excess material from said substrate.

2. The device of claim 1 further comprising:

first and second adjustment mechanisms for securing, respectively, said first and second cutting mechanisms relative to said frame.

3. The device of claim 1 further comprising:

a handgrip removably attachable to said frame.

4. The device of claim 1 wherein said first and second cutting mechanisms are blades removably connected to first and second posts that are slidable relative to said frame.

5. The device of claim 3 wherein said frame is substantially U-shaped an includes a bridge portion and two longitudinally extending arms, said bridge portion having an opening to accept said first post and allow movement of said first post in said first direction, and said arms being operatively connected to said second post such that said second post is capable of movement in both said first and second directions.

6. The device of claim 1 wherein said substrate is a panel of sheetrock.

7. A device for cutting sheetrock, comprising:

a frame defining a plane;

a first blade adjustably connected to the frame for motion perpendicular to the plane;

a second blade adjustably connected to the frame for motion perpendicular to the plane, and for motion toward and away from the first blade;

a first adjuster cooperating with the first blade to secure the first blade relative to the frame; and

a second adjuster cooperating with the second blade to secure the second blade relative to the frame.

8. The device according to claim 7, wherein the frame includes parallel arms, the second blade is connected to the parallel arms, and the second blade is movable along the parallel arms.

9. The device according to claim 8, wherein at least one of the parallel arms is marked with measurements indicating a distance between the first blade and the second blade.

10. The device according to claim 7, wherein at least one of the first blade and the second blade is rotatably connected to the frame.

11. The device according to claim 7, wherein at least one of the first blade and the second blade is connected to the frame by a movable post marked with measurements.

12. A method for cutting a panel of sheetrock, comprising:

selecting a cut depth corresponding to a distance measured from an edge of the panel;

adjusting two opposed blades to provide the selected cut depth;

bringing the two opposed blades in contact with opposed faces of the panel; and

moving the two opposed blades along the opposed faces of the sheetrock parallel to the edge of the panel.

13. The method according to claim 12, further comprising:

breaking the panel at scored lines made by the two opposed blades.