Flattening and Resurfacing Mill

Abstract

A powered cutting apparatus for cutting an elongated work piece, the cutting apparatus including: a base having a top surface fixed to a bottom section; at least one attachment guide removably fixed to the top surface for connecting to a guide rail; a motor fixed to the base at the top surface; the motor includes a shaft which extends past an edge of the top surface; a cutterhead coupled to the motor with a first band and fixed to the bottom section of the base; and where the cutterhead cuts an even plane surface of a cutting surface based on the rotational output of the motor.

Claims

1. A powered cutting apparatus for cutting an elongated work piece, the cutting apparatus comprising: a base having a top surface being approximately flat and fixed to a bottom section comprising walls configured to withstand rotational force; at least one attachment guide removably fixed to the top surface for connecting to a guide rail; a motor fixed to the base at the top surface; the motor comprises a shaft which extends past an edge of the top surface; a cutterhead coupled to the motor with a first band and fixed to the bottom section of the base; and wherein the cutterhead cuts an even plane surface of a cutting surface based on the rotational output of the motor.

2. The powered cutting apparatus for cutting an elongated work piece of claim 1, wherein the cutterhead comprises a cutter shaft coupled to the first band through the bottom section and a cutting tool coupled to the cutter shaft; wherein the top surface creates a plane parallel to the cutter shaft and the cutting tool cuts the elongated workpiece at an angle approximately perpendicular to the plane.

3. The powered cutting apparatus for cutting an elongated work piece of claim 1, further comprising a first adjuster for adjusting the pitch or angle of the top surface of the base relative to the cutting surface, wherein the first adjuster is fixed to the top surface of the base.

4. The powered cutting apparatus for cutting an elongated work piece of claim 3, further comprising a second adjuster for adjusting the pitch or angle of the top surface of the base relative to a cutting surface, wherein the second adjuster is fixed to the top surface of the base.

5. The powered cutting apparatus for cutting an elongated work piece of claim 1, wherein the top surface of the base further comprises at least one rail attachment fixture for attaching the top surface to a rail system.

6. The powered cutting apparatus for cutting an elongated work piece of claim 1, further comprising a first adjuster for adjusting the pitch or angle of the cutterhead relative to the cutting surface, wherein the first adjuster is fixed to the top surface of the base.

7. The powered cutting apparatus for cutting an elongated work piece of claim 1, further comprising a sander coupled to the motor with a second band and adjustably fixed to the bottom section of the base; wherein a location of the sander relative to the cutterhead and a plane of the top surface is adjustable and the attachment guide is adjustably fixable to a guide rail.

8. The powered cutting apparatus for cutting an elongated work piece of claim 6, wherein the first band is releasably coupled to a shaft of the cutterhead and the second band is releasably coupled to a shaft of the sander so that the output of the motor can rotate the cutterhead and the sander at different rotational speeds.

9. A powered cutting apparatus for cutting an elongated work piece, the cutting apparatus comprising: a base having a bottom section and a top surface with drop down attachments configured for releasably coupling to a rail and at least one guide attachment for releasably coupling to a guide rail; a motor fixed to the top surface of the base; a cutterhead coupled to the motor with a first band and rotatably fixed to the bottom section of the base via a shaft, the cutterhead is positioned approximately parallel with the surface of the base; and a sander coupled to the motor with a second band and adjustably fixed to the bottom section of the base; wherein the sander location relative to the cutterhead is adjustable and the guide attachment is adjustably fixable to a guide rail; wherein the sander location relative to the cutterhead and set of guide rails is adjustable with an adjuster.

10. The powered cutting apparatus for cutting an elongated work piece of claim 9, further comprising a crank arm rotationally fixed to the top surface configured to laterally adjust the base in reference to the rails.

11. The powered cutting apparatus for cutting an elongated work piece of claim 9, wherein the cutterhead comprises a removable and adjustable shaft coupled to the first band through the bottom container and a cutting tool coupled to the shaft; wherein the cutting surface angle of the cutting tool is parallel to the shaft rotating in a rotational downward motion towards the elongated work piece and adjustable based on the adjustability of the shaft.

12. The powered cutting apparatus for cutting an elongated work piece of claim 9, further comprising a first adjuster and second adjuster for adjusting the pitch or angle of the base relative to the cutting surface, wherein the first adjuster is adjustably fixed to the base.

13. The powered cutting apparatus for cutting an elongated work piece of claim 12, further comprising a second adjuster for adjusting the pitch or angle of the base relative to a cutting surface, wherein the second adjuster is adjustably fixed to the base.

14. The powered cutting apparatus for cutting an elongated work piece of claim 9, wherein the drop down attachments further comprise at least one fixture means which allow for adjustably attaching the top surface to at least one rail.

15. The powered cutting apparatus for cutting an elongated work piece of claim 9, wherein the sander is coupled to the motor with the second band and adjustably fixed to the bottom container of the base; wherein a location of the sander relative to the cutterhead is adjustable.

16. The powered cutting apparatus for cutting an elongated work piece of claim 9, wherein the first band is releasably coupled to the cutterhead and motor and the second band is releasably coupled to the motor so that the output of the motor can rotate the cutterhead and the sander at different rotational speeds.

17. The powered cutting apparatus for cutting an elongated work piece of claim 9, further comprising a blade attachment removably and rotationally fixed to the bottom section of the base with a blade shaft and at least one tension roller rotatably coupled to the base; wherein the blade attachment is configured to cut the elongated work piece at a cutting surface angle parallel to the shaft rotating in a rotational downward motion towards the elongated work piece and adjustable based on the adjustability of the blade shaft and the at least one tension roller contacts the cutting surface.

18. A method of cutting an elongated workpiece with a powered cutting apparatus comprising: releasably attaching the cutting apparatus to a rail system; releasably attaching an elongated workpiece to the rail system; adjusting the elongated workpiece to be flush or level along a plane of the rail system; adjusting a cutterhead of the powered cutting apparatus to cut along the plane of the elongated workpiece; cutting the elongated workpiece using the cutterhead by having the cutterhead cut downward towards the plane; and moving the apparatus to cut at least a part of the elongated cutting surface.

19. The method of claim 17, further comprising adjusting a sander of the powered cutting apparatus to sand along the plane of the elongated workpiece.

20. The method of claim 18, further comprising sanding the elongated workpiece using the sander along the plane of the elongated workpiece; and rotating the cutterhead and the sander at different rotational speeds wherein a first band is releasably coupled to the cutterhead and a motor and a second band is releasably coupled to the motor so that the output of the motor can rotate the cutterhead and the sander at different rotational speeds.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0025] FIG. 1 is a perspective view of the flattening and resurfacing mill according to one example of the present disclosure;

[0026] FIG. 2 is side view of the flattening and resurfacing mill according to one example of the present disclosure;

[0027] FIG. 3 is an additional perspective view of the flattening and resurfacing mill;

[0028] FIG. 4 is a drive side view of the flattening and resurfacing mill;

[0029] FIG. 5 is a drive side perspective view of the flattening and resurfacing mill;

[0030] FIG. 6 is a back side view of one embodiment of the flattening and resurfacing mill;

[0031] FIG. 7 is a side view of the flattening and resurfacing mill with a saw blade attachment;

[0032] FIG. 8 is bottom view of the flattening and resurfacing mill with the saw blade attachment including a saw blade drive shaft;

[0033] FIG. 9 is a top view of the flattening and resurfacing mill;

[0034] FIG. 10 is an assembled view of one embodiment of the flattening and resurfacing mill with a rail system;

[0035] FIG. 10 is a perspective view of the flattening and resurfacing mill according to one example of the present disclosure;

[0036] FIG. 11 is an additional perspective view of the flattening and resurfacing mill according to one example of the present disclosure;

[0037] FIG. 12 is a bottom view of the flattening and resurfacing mill;

[0038] FIG. 13 is a drive side view of the flattening and resurfacing mill;

[0039] FIG. 14 is a side view of the flattening and resurfacing mill;

[0040] FIG. 15 is a side view of the flattening and resurfacing mill with a saw blade attachment; and

[0041] FIG. 16 is drive side view of the flattening and resurfacing mill with the saw blade attachment including a saw blade drive shaft.

DESCRIPTION OF THE DISCLOSURE

[0042] For purposes of the description hereinafter, spatial orientation terms, as used, shall relate to the referenced aspect as it is oriented in the accompanying drawings, figures, or otherwise described in the following detailed description. However, it is to be understood that the aspects described hereinafter may assume many alternative variations and configurations. It is also to be understood that the specific components, devices, features, and operational sequences illustrated in the accompanying drawings, figures, or otherwise described herein are simply exemplary and should not be considered as limiting.

[0043] As shown in FIGS. 1-16, the present disclosure is directed to a flattening and resurfacing mill 100 that is not limited to, but can cut and sand large elongated surface areas commonly referred to as a slab. The slab or cutting surface may be an elongated board with or without a raw or live edge. The lengths of the elongated cutting surface may be approximately 10 feet. Using a blade 27, a cutterhead 23, and a sanding drum 9 where a substantial surface area of the cutting tool is brought into contact for machining and working the work piece. In particular, where a cutterhead 23 and sanding drum 9 are brought to cut and sand respectfully, on the work piece by way of the type of cutting in the disclosure, the alignment via angle and pitch of the cutting surface of the cutterhead 23 and sanding drum 9 with the work piece is important in establishing efficient and effective cutting operations on the work piece. An improper alignment reduces the quality and efficiency of cutting the work piece by adding angled offsets and miss-cuts. Therefore, when a large surfacing machine is brought across the surface of a work piece a high degree of cutting efficiency is required to maintain the accuracy of the cut.

[0044] FIGS. 1-3 display the flattening and resurfacing mill 100. The flattening and resurfacing mill 100 includes a base 1 with a top surface 3 and bottom section 5. The bottom section is configured to allow for placement and attachment of shafts and to withstand the rotational forces that are typical of a commercial cutting device. The top surface 3 has a removably fixed attachment guide 17. The attachment guide 17 is configured to slidably and adjustably fix to a guide rail. The attachment guide 17 may be circular, rectangular, or any geometric shape to fit a guide rail. The attachment guide 17 may be removably fixed to any edge of the top surface 3 or to the plane of the top surface 3.

[0045] In one embodiment, the top surface 3 extends past the base 1. The bottom section 5 may include arm sections 31 which attach the bottom section 5 to the top surface 3. The arm sections 31 may add additional support to the top surface 3. The arm sections 31 may be configured to allow for a rail attachment means. The arm sections 31 may be configured to allow for a rail to slidably connect and slidably move along the rail using rollers 33.

[0046] A motor 11 or similar rotating means is attached to the top surface 3. The motor 11 or similar rotating means is configured to rotate a shaft 35 of the motor 11 at variable or fixed speeds common of a saw or cutting means. The shaft of the motor 11 may extend past an edge of the top surface 3 to allow for additional attachments.

[0047] A dust collection hookup 21 is partially centered on the surface 3 and connects to the sanding drum 9, seen in FIG. 6 to allow the flow of saw dust and debris created by the cutterhead 23 or sanding drum 9 cutting or sanding the work piece, respectfully, to flow away from the work piece or user. Transporting dust and debris from the work piece aids in an increase in accuracy to the desired outcome of the cut or sanding of the work piece. The dust collection hookup 21 is compatible and connectable to a hose, pipe, or tube to collect debris.

[0048] It is preferred in some non-limiting embodiments or aspects that a blade 27 is removably attached to the flattening and resurfacing mill 100.

[0049] FIGS. 3-5 display a drive side perspective view of the flattening and resurfacing mill 100. As displayed, the motor 11 is rotatably attached to a cutterhead 23 via a cutterhead shaft 37 extending through the bottom section 5 with at least one band 13a, 13b. A cover 19 covers the band 13a, 13b to provide protection from cutting debris as well as provide safety to the flattening and resurfacing mill user. The cover 19 may be removably attached to the base 1. The cutterhead 23 has a cutting tool, internal to the cutterhead 23, coupled to the cutterhead shaft 37 which is configured to rotationally cut when the flattening and resurfacing mill 100 is operating. The cutterhead 23 and cutting tool are aligned and angled so that the cut is even and level along the cutting surface. A plane is created by the top surface 3 of the base 1. The cutting surface, the top surface 3 of the base 1, and the cutterhead shaft 37 are all parallel to the plane of the top surface 3. The cutterhead 23 is configured to rotate so that the cutting edge and cutting direction are perpendicular to the plane of the top surface 3 and cut in a downward direction towards the cutting surface. This advantage allows for an increased cutting surface area, a reduction in tear out of the cutting surface, a more accurate cut, and an increase in duration efficiency. The cutting direction may additionally cut with the grain of the cutting surface.

[0050] At least one adjuster 7 configured for adjusting the pitch or angle of the top surface 3 of the base 1 relative to the cutting surface or rail system is removably and adjustably fixed to the top surface 3. The adjuster 39 may be fixed to the edge of the top surface 3 or to a centered portion of the top surface 3. The adjuster 39 may have a rotating means such as but not limited to gears. Each adjuster 39 may be individually adjustable to lower or raise the top surface 3 as it rests on a rail to align the cutterhead 23 as desired with the cutting surface.

[0051] The top surface 3 may attach to a rail or rail system via a rail attachment fixture 15 (Hookups). The rail attachment fixtures 15 may be along the edge of the top surface 3, the middle portion of the top surface 3, or along the bottom section 5. The rail attachment means may be, but are not limited to, a series of bolt holes, fasteners, plates, or extending bolts. The rail attachment fixtures 15 may be a cut out section of the bottom section 5 to allow for a rail to pass through.

[0052] The motor 11 may be additional rotatably attached to a sanding drum 9 (FIG. 3) with at least one band 13a, 13b. The sanding drum 9 sands the work piece to create a desired smoothness. The grit of the sanding drum 9 can be altered to adjust for a desired finished smoothness of the work piece. The adjuster 7 of the top surface 3 may also be used to adjust the height of sanding drum 9. The sanding drum 9 may have a sanding shaft 41 which rotatably and releasably fixes the sanding drum 9 to the bottom section 5. The sanding shaft 41 may be connected to the shaft of the motor 11 via at least one band 13a, 13b to transfer the rotational output of the motor 11 to the sanding drum 9. Sanding drum can be advantageously used simultaneously with the cutterhead 23 or separately.

[0053] FIG. 5 displays an additional perspective view. Hookups or rail attachment fixtures 15 are along the sides of the top surface 3, but may be located on any portion of the top surface 3, base 1, or bottom section 5. Hookups or rail attachment fixtures 15 may be are used for transporting the flattening and resurfacing mill 100 in regards to the work piece. The top surface 3 may include rail attachment fixtures or hookup 15 and the attachment guide or frame connector 17 for removably fixing the flattening and resurfacing mill 100 to a rail system 200.

[0054] FIG. 7 displays an additional side view including the blade 27 on one embodiment. Blade 27 may be used to cut or shape the workpiece, similarly to a table saw. Blade 27 may include a blade cover 29. Optional blade cover 29 is removably attached to the wall 5 of the base 1. The optional blade cover 29 protects the user from the blade 27 and debris from the work piece. The blade cover 29 may include a moveable or rotatable guard 43 which moves when contacted with the cutting surface. The rotatable guard 43 may be spring loaded to be in a closed position covering the blade 27 when not in contact with the cutting surface.

[0055] FIG. 8 further displays the blade 27 and the blade drive shaft 31. The blade drive shaft 31 is removably attached to the blade 27 and to the motor 11. The motor 11 and blade drive shaft 31 are coupled by at least one band 13. The motor 11, when activated, rotates the band 13, which in turn rotates the blade drive shaft 31, rotating the blade 27. Tension rollers 45 are removably axially coupled to the bottom section 5. The tension rollers 45 may be coupled to the bottom section 5 with springs, dampeners, or any dampening means. The tension rollers 45 are approximately parallel with one of the shafts of the sanding drum 9, cutterhead 23, or blade drive shaft 31. The tension rollers 45 aid in movement of the flattening and resurfacing mill 100 by contacting the cutting surface. The height of the tension rollers 45 adjust in reference to the cutterhead 23 contacting the cutting surface.

[0056] FIG. 9 displays the flattening and resurfacing mill 100 on one embodiment of a rail system 200. The flattening and resurfacing mill 100 travels along the elongated surface of the work piece while connected to the rail system 200. The rail system 200 may direct the flattening and resurfacing mill 100 over the work piece. The rail system 200 may determine the depth of the cut the flattening and resurfacing mill 100 conducts, but the flattening and resurfacing mill 100 may also be adjusted to determine, for example but not limited to, pitch, angle, depth, speed, and duration of the cut in addition to sanding. The rail system may be 10 feet in length, but extensions may extend the mill by 5 to 10 feet.

[0057] The rail system 200 additionally provides the desired height at which the work piece is cut. The flattening and resurfacing mill 100 may move along a rail of the rail system 200 down the elongated surface of the work piece. The rail attachment fixtures 15 removably fix the flattening and resurfacing mill 100 to the rail system 200. The rail system 200 may be configured so that a tray for holding the elongated cutting surface is below the flattening and resurfacing mill 100 attached to a rail. At least one vertical beam connects the flattening and resurfacing mill 100 attached to a rail to the tray for holding the elongated cutting surface. Preferably, the at least one vertical beam is able to move in a horizontal position and the rail which the flattening and resurfacing mill 100 is attached to may move in a vertical direction. This allows for the adjustment and movement path for the flattening and resurfacing mill 100 to travel over the elongated cutting surface. The crank arm or adjuster 7 may be used to laterally adjust the flattening and resurfacing mill 100. An electronic system, a hydraulic system, or any similar system may be used to ease the user in the adjustment of the flattening and resurfacing mill 100. A user may use the crank arm 7 to laterally adjust the flattening and resurfacing mill 100 along the plane of the cutting surface. This advantageously allows the user to cut more of the cutting surface at a faster rate than a traditional router elongated cutting surface method. The sander 9 may also be used in a like matter.

[0058] FIGS. 10-15 display an alternative embodiment of the flattening and resurfacing mill 100. The flattening and resurfacing mill 100 includes a base 1 with a top surface 3 and bottom section 5. The bottom section is configured to allow for placement and attachment of shafts and to withstand the rotational forces that are typical of a commercial cutting device. The top surface 3 has a removably fixed attachment guide 17. The attachment guide 17 is configured to slidably and adjustably fix to a guide rail. The attachment guide 17 may be circular, rectangular, or any geometric shape to fit a guide rail. The attachment guide 17 may be removably fixed to any edge of the top surface 3 or to the plane of the top surface 3.

[0059] While aspects of a flattening and resurfacing mill are shown in the accompanying figures and described hereinabove in detail, other aspects will be apparent to, and readily made by, those skilled in the art without departing from the scope and spirit of the invention. Accordingly, the foregoing description is intended to be illustrative rather than restrictive. The invention described hereinabove is defined by the appended claims and all changes to the invention that fall within the meaning and the range of equivalency of the claims are to be embraced within their scope.