US-20260124688-A1 - TRIMMING TOOL AND METHOD OF USE

US20260124688A1US 20260124688 A1US20260124688 A1US 20260124688A1US-20260124688-A1

Abstract

An example trimming tool includes a floating base having a first side and an opposite, second side, a first rail, and a second rail. At least the second side of the floating base, the first rail and the second rail define a workspace having a first opening and a second opening. The trimming tool also includes a milling apparatus, attached to the floating base, having a base on the first side of the floating base and a milling head on the second side of the floating base. The milling head is spring loaded. The floating base and milling apparatus are configured to remove at least a portion of a foam layer in the workspace.

Inventors

Jordan Byron Rothwell

Assignees

Jordan Byron Rothwell

Dates

Publication Date: 20260507
Application Date: 20251106

Claims (20)

1 . A trimming tool comprising: a floating base having a first side and an opposite, second side, a first rail, and a second rail wherein at least the second side of the floating base, the first rail and the second rail define a workspace having a first opening and a second opening; and a milling apparatus, attached to the floating base, having a milling head on the second side of the floating base, wherein the milling head is spring loaded, wherein the floating base and milling apparatus are configured to remove at least a portion of a foam layer in the workspace.
2 . The trimming tool of claim 1 , wherein the first rail and the second rail include linear portions to maintain the floating base against a surface.
3 . The trimming tool of claim 1 , wherein the first rail, the second rail, and the floating base are unitary.
4 . The trimming tool of claim 1 , wherein the floating base includes a collection port configured to allow millings to pass through a collection port opening and out of the workspace, wherein the collection port is connected to a tube configured to provide suction.
5 . The trimming tool of claim 1 , wherein the milling apparatus includes a handle and a motor configured to power the milling head.
6 . The trimming tool of claim 1 , wherein the milling head includes a plurality of protrusions extending about a circumference of the milling head and a guide surface that protrudes from the bottom of the milling head.
7 . The trimming tool of claim 6 , wherein the plurality of protrusions include spikes and the guide surface protrudes from the bottom of the milling head a length equal to the length of one of the plurality of protrusions.
8 . The trimming tool of claim 6 , wherein the milling head includes a protective coating.
9 . The trimming tool of claim 1 , wherein the milling head is disposed closer to the first opening than the second opening, wherein the foam layer is configured to enter the workspace through the first opening.
10 . The trimming tool of claim 1 , wherein the milling head is attached to the floating base by a fastener that extends through the milling head and through an opening in the floating base.
11 . A method of using a trimming tool comprising: providing a trimming tool including a floating base having a first side and an opposite, second side, a first rail, and a second rail wherein at least the second side of the floating base, the first rail and the second rail define a workspace having a first opening and a second opening, and a milling apparatus, attached to the floating base, having a milling head on a second side of the floating base, wherein the milling head is within the workspace; moving the trimming tool along a surface such that at least a portion of a foam layer enters the workspace; and milling at least a portion of the foam layer such that the surface and the portion of the foam layer that is milled are flush.
12 . The method of claim 11 , including the step of removing scrap foam being milled through a collection port of the floating base.
13 . The method of claim 12 , wherein the step of removing the scrap foam includes suctioning the scrap foam through the collection port and through a tube attached to the collection port.
14 . The method of claim 12 , wherein the step of removing scrap foam and the step of milling are performed concurrently.
15 . The method of claim 11 , wherein the surface is formed by structural framing studs and an insert panel.
16 . The method of claim 11 , wherein the foam layer is a rigid foam layer and including the step of applying the rigid foam layer to creates a seal between the structural framing studs and insert panel.
17 . The method of claim 11 , including the step of turning on the milling head prior to the step of moving the trimming tool, wherein the milling apparatus includes a handle and a motor and the milling head is spring loaded.
18 . The method of claim 17 , including the step of activating the milling head by a trigger of the handle; and powering the motor using a battery.
19 . The method of claim 11 , including the step of applying drywall to the surface and the portion of the foam layer are flush.
20 . The method of claim 11 , wherein a trailing edge of the second opening is about 1 / 4 inch above the first rail and the second rail.

Description

This application is a continuation of U.S. application Ser. No. 16/044,690, filed Jul. 25, 2018, which claims priority to U.S. Provisional Application Ser. No. 62/536,705, filed Jul. 25, 2017. BACKGROUND This disclosure relates to devices and methods for eliminating extraneous foam or other materials used in the construction of walls, such as insulated wall panels, and a method of doing the same. Various methods have been used to produce foam filled wood stud walls. One particular method, developed by the Assignee of the present disclosure, is particularly suited to prefabricated walls and is described in U.S. Pat. No. 5,273,693. In that method, a half completed stud wall is introduced into an apparatus comprising a backplate and a moveable dam having a removable sheet and a compressible membrane. The exterior sheathing of the stud wall is placed against the backplate. The stud wall is backed with any suitable exterior sheathing, such as asphalt-impregnated fiber board. The removable sheet is draped over the interior of the stud wall. The compressible membrane is placed over the removable sheet and the moveable dam urges the backplate, stud wall, removable sheet and compressible membrane together. The compressible membrane forms a seal between the dam and the studs and is urged into the wall cavity reducing the volume of the cavity. Interfaces used for prefabricating panels result in large assembly lines, increasing manufacturing time and expense, and making it more difficult to retrofit existing assembly lines. A foam or foam-forming mixture is introduced between the sheathing and the moveable dam having the removable sheet and the compressible membrane, which is temporarily positioned against the interior side of the studs. The foam or foam-forming mixture is introduced by a “spray-pour” method. In this type of method, a spray-type urethane foam is injected between the exterior sheathing and the dam using an atomizing spray nozzle having a tube to direct the trajectory of the spray. The foam is then permitted to rise freely between the sheathing and the dam and is allowed to set. After allowing sufficient setting time to elapse, the dam is moved to the next upper unfilled section of the stud wall while the removable sheet and the compressible membrane are unrolled in advance of the moveable dam and the next bath of foam or foam-forming mixture is introduced into the wall. The wall can therefore be filled in a series of spray-pours. More recently, the Assignee of the present disclosure developed panels that included rigid foam panels, as described in U.S. Pat. No. 8,365,497. Insulated panels include exterior sheathing, studs, rigid foam panels and spray/pour foam that is cured in place. The rigid foam panels are placed up against the sheathing between the studs, and the spray/pour foam is used to fill in the void between the studs and the rigid foam panels. In some examples, the rigid foam panels may have beveled sides, or be placed by guides or spacers. Additional layers of rigid foam panels and/or spray/pour foam may be applied over the original layer of rigid foam panels. The application and use of the rigid foam panels, the spray/pour foam, and other foam can leave an uneven, rigid foam layer on the surface of the resulting product. The uneven, rigid foam layer results in a process to reduce the rigid foam layer flush with a stud to produce a uniform panel surface to which drywall or some other product can be fastened. The process is labour intensive and produces large chunks of scrap foam that must be manually gathered for disposal. Automating the process has proven difficult due to the lack of perfect alignment between the studs, the lack of uniformity amongst studs, and a non-uniform recess depth where the rigid foam layer is provided. SUMMARY In one non-limiting embodiment, a trimming tool includes a floating base having a first side and an opposite, second side, a first rail, and a second rail. At least the second side of the floating base, the first rail and the second rail define a workspace having a first opening and a second opening. The trimming tool also includes a milling apparatus, attached to the floating base, having a base on the first side of the floating base and a milling head on the second side of the floating base. The milling head is spring loaded. The floating base and milling apparatus are configured to remove at least a portion of a foam layer in the workspace. In another non-limiting embodiment, a method of using a trimming tool includes providing a trimming tool. The trimming tool includes a floating base having a first side and an opposite, second side, a first rail, and a second rail. At least the second side of the floating base, the first rail and the second rail define a workspace having a first opening and a second opening. The trimming tool includes a milling apparatus, attached to the floating base, having a base on the first side of the floating base and a milling he