Cutting apparatus

Claim 1

Apparatus for cutting a block into a structure having multiple diagonal cuts forming a uniform array of pyramidal-shaped projections and comprising; a frame, a table supported in the frame at a lower position of the frame, means for driving the table in a linear horizontal direction at a constant controlled speed during a diagonal cut, at least one cutting hot wire, means supporting the hot wire from the frame at a position over the table, and means for driving the hot wire support means in a linear vertical direction at a constant controlled speed during a diagonal cut, said table including a platform upon which the block is retained and a table support, said platform being rotatable relative to said table support as well as being moveable in a linear horizontal direction along with said table support.

Claim 17

A method of cutting foam blocks into predetermined sloped patterns forming a uniform array of pyramidal-shaped projections, said method comprising the steps of; supporting the block on a table in a framework, providing a means to carry at least one hot wire disposed over the table and spaced from the table in a precutting position of the hot wire, providing linear drive to the table to cause the table to move linearly at a constant speed in only one horizontal direction during a first cutting sequence, providing linear drive to the hot wire so as to move the hot wire linearly at a constant speed in only one vertical direction during the first cutting sequence, controlling the table and hot wire drives to provide product cutting along a predetermined diagonal path including simultaneous drive at relative constant speeds to control the shape of the diagonal cut and thus the shape of the pyramidal-shaped projections, rotating the table and thus the block through an angle of approximately 90°, and cutting the block in a second cutting sequence so as to ultimately form the pyramidal-shaped projections in the block.

Claim 18

A method of cutting foam blocks into predetermined sloped patterns forming a uniform array of pyramidal-shaped projections, said method comprising the steps of; supporting the block on a table in a framework, providing a means to carry at least one hot wire disposed over the table and spaced from the table in a precutting position of the hot wire, providing linear drive to the table to cause the table to move linearly at a constant speed in only one horizontal direction during a first cutting sequence, providing linear drive to the hot wire so as to move the hot wire linearly at a constant speed in only one vertical direction during the first cutting sequence, controlling the table and hot wire drives to provide product cutting along a predetermined diagonal path including simultaneous drive at relative constant speeds to control the shape of the diagonal cut and thus the shape of the pyramidal-shaped projections, rotating the table and thus the block through an angle of approximately 90°, and cutting the block in a second cutting sequence so as to ultimately form the pyramidal-shaped projections in the block.