U.S. patent application number 11/779035 was filed with the patent office on 2008-02-21 for system for forming a miter joint.
This patent application is currently assigned to Black & Decker. Invention is credited to Frederick R. Bean, Louis Gibbons, Robert H. Gifford, Steven McClaskey, Gregory S. Snider, Terry L. Turner.
Application Number | 20080041211 11/779035 |
Document ID | / |
Family ID | 39083052 |
Filed Date | 2008-02-21 |
United States Patent
Application |
20080041211 |
Kind Code |
A1 |
Gibbons; Louis ; et
al. |
February 21, 2008 |
System for Forming a Miter Joint
Abstract
The present invention is directed toward a system for forming
miter joints including a miter saw and an angle gauge. The miter
saw includes a platform with a kerf slot and a pair of arcuate
slots. Each arcuate slot includes an associated rail located on the
underside of the platform. A fence is coupled to each of the rails
such that the fence may be pivoted with respect to the platform.
The angle measurement tool is a one-handed tool including spring
loaded paddles that measure the angle between intersecting
surfaces. The angle measurement tool connects to the miter saw to
permit the transfer of the measured angle to the fences.
Inventors: |
Gibbons; Louis;
(Stevensville, MD) ; Snider; Gregory S.; (Bel Air,
MD) ; Bean; Frederick R.; (Finksburg, MD) ;
Turner; Terry L.; (Towson, MD) ; McClaskey;
Steven; (Baltimore, MD) ; Gifford; Robert H.;
(New Freedom, PA) |
Correspondence
Address: |
EDELL, SHAPIRO & FINNAN, LLC
1901 RESEARCH BOULEVARD, SUITE 400
ROCKVILLE
MD
20850
US
|
Assignee: |
Black & Decker
Newark
DE
|
Family ID: |
39083052 |
Appl. No.: |
11/779035 |
Filed: |
July 17, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60822707 |
Aug 17, 2006 |
|
|
|
Current U.S.
Class: |
83/473 ; 33/534;
83/468.3 |
Current CPC
Class: |
B27B 27/10 20130101;
Y10T 83/865 20150401; Y10T 83/762 20150401; B27B 5/29 20130101;
B27B 27/08 20130101; B23D 45/042 20130101; Y10T 83/773 20150401;
B27G 5/023 20130101; Y10T 83/7705 20150401 |
Class at
Publication: |
83/473 ; 33/534;
83/468.3 |
International
Class: |
B23D 33/02 20060101
B23D033/02 |
Claims
1. A miter saw comprising: a platform including a first surface and
a an opposed second surface; a cutting device coupled to the first
surface of the platform; a kerf slot formed into the platform; a
first generally arcuate slot formed in the platform and disposed in
spaced relation from the kerf slot; a first generally arcuate rail
coupled to the second surface of platform; a first fence
comprising: a block operable to support a workpiece, and a coupling
member slidingly connected to the first generally arcuate rail;
wherein the first fence is displaceable along the first arcuate
rail to reorient the first fence from a first position within the
first arcuate slot to a second position within the first arcuate
slot, and vice versa.
2. The miter saw of claim 1 further comprising: a second generally
arcuate slot formed in the platform and disposed in spaced relation
from the kerf slot; a second generally arcuate rail coupled to the
second surface of platform; a second fence comprising: a block
operable to support a workpiece, and a coupling member that
slidingly engages the generally arcuate rail; wherein the second
fence is displaceable along the first arcuate rail to reorient the
second fence from a first position within the second arcuate slot
to a second position within the second arcuate slot.
3. The miter saw of claim 2, wherein the first fence is linked to
the second fence such that displacement of the first fence causes a
corresponding displacement of the second fence.
4. The miter saw of claim 1, wherein displacement of the first
fence from the first fence position to the second fence position
pivots the fence to alter the angle of the fence with respect to
the kerf slot.
5. The miter saw of claim 1, wherein the platform further comprises
a mechanism operable to incrementally adjust the position of the
fence on the platform.
6. The miter saw of claim 5, wherein the adjustment mechanism
comprises: a gear rack disposed on the second surface of the
platform; a gear operable to selectively communicate with the gear
rack; and an actuator coupled to the gear such that engaging the
actuator drives the gear along the rack, incrementally displacing
the fence on the platform.
7. The miter saw of claim 1, wherein the fence further comprises a
fence lock mechanism to secure the fence in a stationary position
with respect to the platform.
8. The miter saw of claim 7, wherein: the coupling member comprises
a channel that slidingly captures the rail; and the fence lock
mechanism comprises: a rod coupling the fence to the coupling
member; and a lever to reorient the coupling member from a first
position, in which the rail slides within the channel, to a second
position, in which the rail does not slide within the channel.
9. A method of forming a miter joint comprising: (a) providing the
miter saw of claim 1; (b) measuring an angle between intersecting
surfaces utilizing an angle measurement tool; (c) transferring the
measured angle from the angle measurement tool to the miter saw;
and (d) acting upon a workpiece with the cutting device.
10. The method of claim 9, wherein: the angle measurement tool
comprises a first plate and a second plate, the first plate
configured to contact a first intersecting surface and the second
plate configured to contact a second intersecting surface; (b)
comprises: (b.1) contacting the first plate to the first
intersecting surface, and (b.2) contacting the second plate to the
second intersecting surface; and (c) comprises: (c.1) coupling the
angle measurement tool to the platform, and (c.2) repositioning the
first fence to contact the first plate.
11. A miter joint forming system comprising: (a) a base station
including: a platform including a first surface and a an opposed
second surface, a cutting device coupled to the first surface of
the platform, a kerf slot formed into the platform, a first
generally arcuate slot formed in the platform and disposed in
spaced relation from the kerf slot, a first generally arcuate rail
coupled to the second surface of platform, a first fence
comprising, a block operable to support a workpiece, and a coupling
member that slidingly engages the first generally arcuate rail, a
second generally arcuate slot formed in the platform and disposed
in spaced relation from the kerf slot, a second generally arcuate
rail coupled to the second surface of platform, and a second fence
comprising: a block operable to support a workpiece, and a coupling
member that slidingly engages the second generally arcuate rail,
wherein the first and second fences are displaceable to pivot the
fences from a first fence position to a second fence position, and
vice versa; and (b) a measurement tool to measure the angle between
intersecting surfaces.
12. The miter joint forming system of claim 11, wherein the
measurement tool comprises: a housing; a rod displaceable within
the housing; a first plate and a second plate, each plate in
communication with the rod such that translation of the rod alters
an angle between the plates.
13. The miter joint forming system of claim 11, wherein the
measurement tool removably couples to the base station to enable
the transfer of an angle measured by the tool to the fences of the
base station.
14. An angle gauge comprising: a housing having a proximal end and
a distal end, the housing including: a rod having a first end and a
second end, an actuator block coupled to the rod second end, and a
biasing member to bias the rod toward the distal end of the
housing; a first strut in communication with the actuator block; a
second strut in communication with the actuator block; a first
plate coupled to the first strut; and a second plate coupled to the
second strut, wherein translation of the actuator block repositions
the first and second struts to alter an angle between the first
plate and the second plate.
15. A method for forming a miter joint comprising: (a) providing an
angle measurement tool comprising: a housing having a proximal end
and a distal end, the housing including: a rod having a first end
and a second end, an actuator block coupled to the rod second end,
a biasing member to bias the rod toward the distal end of the
housing and drive the plates from a first plate position to a
second plate position, and an actuator configured to selectively
release the rod and permit the biasing member to drive the rod; a
first strut in communication with the actuator block; a second
strut in communication with the actuator block; a first plate
pivotally coupled to the first strut; and a second plate pivotally
coupled to the second strut, wherein the translation of the rod
alters an angle between the first plate and the second plate; (b)
measuring the angle between first and second intersecting surfaces
by: orienting the plates proximate a corner, engaging the actuator
to release the rod and permit the biasing member to drive the
plates toward the intersecting surfaces until the first plate
contacts the first intersecting surface and the second plate
contacts the second intersecting surface, (c) releasing the
actuator to secure the plates at the measured angle. (d) coupling
the tool to a base station, the base station including first
displaceable fence and a second displaceable fence; (e) reorienting
the first fence into contact with the first plate; (f) reorienting
the second fence into contact with the second plate; (g) removing
the measurement tool from the base station.
16. The method of claim 14, wherein: the base station comprises: a
platform including a first surface and a an opposed second surface,
a cutting device coupled to the first surface of the platform, a
kerf slot formed into the platform, a first generally arcuate slot
formed in the platform and disposed in spaced relation from the
kerf slot, a first generally arcuate rail coupled to the second
surface of platform, a first fence comprising: a block operable to
support a workpiece, and a coupling member slidingly connected to
the first generally arcuate rail, a second generally arcuate slot
formed in the platform and disposed in spaced relation from the
kerf slot, a second generally arcuate rail coupled to the second
surface of platform, a second fence comprising, a block operable to
support a workpiece, and a coupling member that slidingly engages
the generally arcuate rail; (d) comprises (d.1) sliding the first
fence along the first generally arcuate rail to reorient the first
fence into contact with the first plate; and (e) comprises (e.1)
sliding the second fence along the second generally arcuate rail to
reorient the second fence into contact with the second plate.
17. The method of claim 14 further comprising: (h) orienting a
workpiece on the fence; and (i) acting on the workpiece with a
cutting device.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a nonprovisional of U.S. Provisional
Application No. 60/822,707 entitled "System for forming a Miter
Joint" and filed on 17 Aug. 2006, the disclosure of which is hereby
incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0002] This invention relates to a system for forming a miter
joint, and, in particular, to a system including a base station and
an angle measurement tool operable to measure the angle between
intersecting surfaces and then transfer the direct measurement to
the base station.
BACKGROUND OF THE INVENTION
[0003] Carpenters are often required to join pieces of material
(i.e. wood, composites, etc.) at a corner. When joining the pieces
of material, the contacting ends of the pieces must be mitered in
order to match the angle of the corner and produce an aesthetically
pleasing joint. The first step needed to create a proper corner
joint is to measure the angle between the converging surfaces. Once
the angle is known, the measured angle is bisected and the
carpenter's mitering tools are set to the value of the bisected
angle. Both converging pieces of material are then cut to the
bisected angle. When joined, the pieces of material meet at an
angle equal to the measured angle, creating a proper corner
joint.
[0004] When corners meet at a right (90.degree.) angle, the
mitering process is relatively simple. Corners that require miter
joints, however, are rarely a perfect right angle. A nominal `right
angle` can, in practice, vary by several degrees on either side of
the accepted right angle. When pieces of material must be joined at
an acute or obtuse angle, the task of creating a proper corner
joint becomes much more complex. For example, a pair of walls may
converge at 88.5.degree. at a ceiling, 90.3.degree. midway between
ceiling and floor, and 91.6.degree. at the floor. These varying
angles must be accurately and quickly measured, and the measurement
must then be accurately and quickly transferred to a mitering tool
(such as a miter saw).
[0005] Traditionally, mitered joints are created using a mitering
tool such as a miter saw (also called a chop saw or drop saw). A
miter saw makes cuts by pulling or pivoting a spinning circular saw
blade down onto a workpiece of material in a short, controlled,
chopping motion. The workpiece is typically held against a fence,
which provides a standard cutting angle between the blade and the
longest workpiece edge. Typically, the standard cutting angle of
the fence is fixed at 90.degree.. A primary feature of a miter saw
is the miter index, which allows the angle of the saw blade to be
changed relative to the fence (i.e., the blade can be rotated left
to right to set it at an angle with respect to the fence). While
many miter saws enable one-degree incremental changes to the miter
index, many also provide "stops" that allow the miter index to be
quickly set to common angles (such as 15.degree., 30.degree., or
45.degree.). A compound feature (i.e., a compound miter saw)
further allows the angle of the cutting blade to be changed
relative to the horizontal plane. Thus, the blade can be angled
left or right (called the miter angle); in addition, the blade can
be tilted side to side (called the bevel angle), which allows the
saw to be used for bevel cutting. Most compound features allow the
angle to be set between 0.degree. and 50.degree., while a
less-common "double-bevel" allows the angle to be set between
-50.degree. and 50.degree..
[0006] While current miter saws provide an effective means to
create miter edge, they are prone to inaccurate measurements. Using
the scale on a miter saw to cut miters for imperfect angles can
result in poorly fitting corner joints on door frames, window trim,
and all types of moldings. This is especially important for large
crown moldings, where a small error in angle could translate into a
large visible gap between two pieces of material. A miter saw,
furthermore, requires a user to take a direct measurement of an
angle using, e.g., a protractor or other angle gauge, and then to
correlate that measurement with the miter index of the saw,
manually adjusting the position of the blade with respect to the
fence (and thus the workpiece). Thus, the angle of the crosscut is
an indirect measurement, which is prone to inaccurate transfer to
the miter saw.
[0007] An angle gauge may also be used to transfer the measured
angle directly to the workpiece. While the angle defined by the
conjoined walls will be accurately captured, error may be
introduced when the measurement is transferred to the workpiece.
For example, the measurement is transferred by marking the board to
be cut with a pencil, and then the cut must be made along the
pencil line. The pencil line itself may not accurately reflect the
true position of the rules, and the cut along said line may
introduce still further error because the operator of the miter saw
must visually guide the saw along the pencil line. Errors may
result from other sources including making incorrect measurements,
incorrectly setting the miter index value, or from differences in
scale between the measuring and cutting devices.
[0008] Consequently, it is desirable to provide a system wherein
the crosscut made into a workpiece is a direct measurement of the
corresponding corner. It is further desirable to provide a system
that eliminates the step of transferring a measured angle to a
workpiece, as well as the step of requiring a craftsman to cut
carefully along said angle. A system is also needed that eliminates
the step of reading a miter angle setting from a tool and setting
the miter saw to the setting.
SUMMARY OF THE INVENTION
[0009] The present invention relates to a system and method for
measuring a corner angle and then transferring the measurement to a
cutting device. The system enables a user to transfer the actual
angle of a corner to a miter saw without the additional steps of
taking a separate measurement of the angle and/or performing any
calculations. Thus, the resulting mitered joint may be cut to match
the actual angle of the corner rather than a nominal angle.
[0010] Thus, the present invention is directed toward a system
forming a miter joint including a measurement tool and a base
station. The measurement tool may include a pair of pivoting plates
operable to measure acute, obtuse, and 90.degree. angles between
intersecting work surfaces such as conjoined walls. The measurement
tool is portable, and releasably connects to the base station. The
base station may include a cutting device (e.g., a miter/drop saw),
a cutting deck, and fences pivotally coupled to the deck. In
operation, a user measures a corner angle by placing each plate of
the measurement tool against a respective one of the intersecting
work surfaces. The measured angle is then transferred to the fences
of base station by placing the measurement tool in a predetermined
position onto the base station, and then pivoting the fences toward
the plates until the fences contact the plates. A fine adjustment
mechanism may be engaged to insure proper abutment of the fences
with the plates of the measurement tool. The fences are then locked
into position, orienting the fences with respect to the blade at a
proper miter angle for the measured corner. That is, the miter
angle is the actual, measured angle of the corner, and no further
adjustment or measurement transfer is required. A workpiece (e.g.,
crown molding) may then be placed on a fence, oriented in the same
manner the workpiece is positioned on the wall. The cutting device
may then be utilized to cut the workpiece.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of the system for forming a
miter joint according to an embodiment of the present
invention.
[0012] FIG. 2 is a perspective view of the base station shown of
FIG. 1 with the cutting tool removed for clarity.
[0013] FIG. 3A is a bottom view of the base station of FIG. 2.
[0014] FIGS. 3B and 3C are close-up views of the underside of the
base station, showing the fine adjustment mechanism.
[0015] FIGS. 4A and 4B are top views of the base station of FIG. 2,
showing displacement of the fences from a first position to a
second position.
[0016] FIGS. 5A and 5B are close-up views of the base station
platform, showing the fence lock mechanism.
[0017] FIGS. 6A and 6B are perspective view of the base station of
FIG. 2, showing the extension of the fences from a first position
to a second position.
[0018] FIG. 7 illustrates a perspective view of the angle gauge of
FIG. 1 in isolation.
[0019] FIG. 8 illustrates an exploded view of the angle gauge shown
in FIG. 7.
[0020] FIGS. 9A and 9B illustrate perspective views of the angle
gauge shown in FIG. 7, showing the movement of the plates from a
first position to a second position.
[0021] FIGS. 10A-10D illustrate the operation of the system for
forming a miter joint shown in FIG. 1.
[0022] Like reference numerals have been used to identify like
elements throughout this disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0023] FIG. 1 is a perspective view of the system for forming a
miter joint in accordance with an embodiment of the present
invention. As illustrated, the system for forming a miter joint 100
may include a base station 110 with a cutting device 120, and a
measurement tool 130 (also called an angle gauge) that removably
couples to the base station.
[0024] The cutting device 120 may include any device operable to
cut a workpiece WP (e.g., wood, aluminum, crown molding, etc). By
way of example, the cutting device 120 may include manual and
powered saws including, but not limited to, hand saws, chop saws,
drop saws, miter saws, sliding saws, etc. The cutting device 120
may be separate from the base station 110, or may be coupled
thereto. In the embodiment shown in FIG. 1, the cutting device 120
is a drop/chop saw (with a rotating circular saw blade) coupled to
the base station 110 using fasteners. Typically, the cutting device
120 is fixed to the base station 110 such that the miter angle of
the cutting device 120 is held constant at about 90.degree..
Alternatively or in addition to, the cutting device 120 may be
adapted to move along a vertical plane so that the bevel angle with
respect to the workpiece WP may be adjusted (e.g., the saw may
bevel approximately 45.degree.). For this reason, one or both of
the sliding fences may possess an angular edge that allows the
blade to layover to the bevel maximum without touching the fences
(discussed in greater detail below).
[0025] FIG. 2 illustrates the base station of FIG.1, with the
cutting device removed for clarity. The base station 110 includes a
cutting deck or platform 200 with a kerf slot or cutting channel
210 formed therein. The kerf slot 210, which receives the blade of
the cutting device 120, extends diametrically along the deck 200 to
define a cutting area. The kerf slot 210 may be any dimension
suitable for its intended purpose (i.e., to provide clearance for
saw blades of various dimensions). The deck 200 may also include a
groove or guide slot 215 along which a fence support 217A, 217B
travels (discussed in greater detail below).
[0026] The deck 200 may be configured to stand on a supporting
surface such as a table, the floor, the ground, etc. To this end,
the deck 200 may include one or more foot members 220 operable to
cooperatively support the deck over/on a supporting surface. Each
foot member 220 may be formed from any suitable material such as
rubber, plastic, wood, metal, etc. The foot members 220 may be
integrated into the deck 200, or may be attached to the deck via
fasteners such as bolts or screws. The deck 200 may further include
a notch 230 that receives a tab or tabs located on the angle gauge
130, securing the angle gauge on the base station 110 and/or
guiding the angle gauge into its proper position on the deck
200.
[0027] The base station 110 may also be adapted to connect to a
miter saw stand in a manner similar to that described in U.S.
patent application Ser. No. 11/298,272 (to Snider), entitled "Tool
Support Device", the disclosure of which is incorporated herein by
reference in its entirety. By way of specific example, the base
station 110 may connect to a deck that, in turn, connects to a
miter saw stand.
[0028] The base station 110 further includes fences 240 to guide a
workpiece WP toward the cutting area (and thus the saw) at a
desired angle. Specifically, a first fence 240A may be oriented on
one side of the kerf slot 210, while a second fence 240B is
oriented on the other side of the kerf slot, opposite the first
fence. Each fence 240A, 240B possesses a proximal end 250 (the end
closer to the kerf slot 210) and a distal end 260 (the end closer
to the perimeter of the deck 200). The proximal end 250 may define
a pivot point about which each fence 240A, 240B may pivot.
Together, the fences 240A, 240B define an angle that is bisected by
the kerf slot 210. The angle between the fences may be altered by
pivoting the fences about their respective pivot points (discussed
in greater detail below).
[0029] As mentioned above, the cutting device 120 may be adapted to
move along a vertical plane so that the bevel angle with respect to
the workpiece WP may be adjusted. For this reason, one or both of
the fences 240A, 240B may possess an angled edge that allows the
blade to layover to the bevel maximum without touching the fences.
For example, the proximal end 250 of the first fence 240A may slope
(angle) downward in the direction of the kerf slot 210 to
accommodate the beveling of the cutting device 120.
[0030] Each fence 240A, 240B is repositionable along the deck 200
such that each fence pivots about a pivot point. As illustrated in
FIG. 2, a pair of arcuate slots or channels 270A, 270B is formed
into the deck 200. Specifically, a first arcuate slot 270A is
formed on one side of the kerf slot 210 and a second arcuate slot
270B formed on the opposite side of the kerf slot. The arcuate
slots 270A, 270B are mirror images of each other, being
symmetrically divided by the kerf slot 210. The dimensions of the
arcuate slots 270A, 270B is not particularly limited, and may be
configured to provide the desired degree of fence pivot.
[0031] Each fence 240A, 240B is coupled to the deck 200 such that
it moves along its associated arcuate slot 270A, 270B, altering the
angle the fence with respect to the kerf slot 210 and, as such, the
angle the workpiece WP enters the cutting area. For example, each
fence 240A, 240B may be coupled (e.g., connected) to a fence
support 217A, 217B, which, in turn, may be coupled to the deck 200
such that it moves along a guide slot 215 formed into the top
surface of the deck. Consequently, moving a fence support 217A,
217B along its corresponding guide slot 215 repositions the fence
240A, 240B along the top of the deck 200, moving about its pivot
point. Each fence support 217A, 217B may further be coupled to
conventional extension members 219 configured to extend outward
from the deck, accommodating workpieces WP of various lengths.
[0032] The base station 110 may also include a rail mechanism
utilized to reposition the fences 240A, 240B along the deck 200.
FIG. 3A is a bottom perspective view of the table of FIG. 2. In the
embodiment illustrated, a rod 300 extends through each fence 240A,
240B to the underside of the deck 200. A rail or rib 305 (e.g., a
generally arcuate rail) is formed into the surface, being
substantially coextensive the arcuate slot 270A, 270B. A shoe 310,
coupled to the rod 300, includes a groove 330 that mates with the
rail 305. The shoe 310 rides along the rail 305; consequently,
applying a force to a fence 240A, 240B drives the fence along the
rail, pivoting the fence about a pivot point located, e.g., at the
proximal end 250 of the fence.
[0033] The repositioning of the fences is illustrated is FIGS. 4A
and 4B. As illustrated, the fences are moveable from a first fence
position (FIG. 4A) to a second fence position (FIG. 4B) (and vice
versa) by manually moving the fences (indicated by arrows). Each of
the guide slot 215 (on the top surface of the deck) and the rail
305 (on the bottom surface of the deck) may work independently or
collectively to pivot each fence 240A, 240B about its proximal end
pivot point. The degree of fence pivot may be limited by the
dimensions of the arcuate slots 270A, 270B and/or the guide slot
215. By way of example, each fence 240A, 240B may be adapted to
pivot approximately 176.degree. through a point that is
perpendicular to the kerf slot 210. In other words, the fences
240A, 240B may rotate 88.degree. clockwise and 88.degree.
counterclockwise from a normal 0.degree. reference point oriented
perpendicular to the drop direction of the blade of the cutting
device 120.
[0034] The base station 110 may further include a fine adjustment
mechanism operable to incrementally reposition each fence 240A,
240B along the deck 200. Referring back to FIG. 3A, a rack gear 350
may be formed into the bottom surface of the deck 200. A pinion
gear 355, in communication with a shaft 360, is coupled to the
fence 240A, 240B. The pinion gear 355 meshes with the rack gear 350
such that rotation of the shaft drives the fence 240A, 240B along
the rack gear 350, in turn driving the fence along the rail,
pivoting it. The fine adjustment mechanism provides incremental
(e.g., in increments less than a degree) adjustment of the fences
to bring the fences into precise contact with the plates of the
angle gauge 130. The operation of the fine adjustment mechanism is
explained with reference to FIGS. 3A-3C. A user engages an actuator
365 (e.g., a knob) to translate (push/pull) the pinion gear 355
into engagement (FIG. 3C) and out of engagement (FIG. 3B) with the
rack gear 350. Rotating the actuator 360 clockwise or
counterclockwise drives the fence as described above, moving the
fence along the rail 305.
[0035] While the fences 240A, 240B may be configured to pivot
independently of each other, in the embodiment illustrated in FIG.
3A, the fences are linked such that movement of the first fence
240A causes a corresponding movement of the second fence 240B, and
vice versa. Specifically, a first gear 370A and a second gear 370B
having intermeshing teeth are rotatably mounted about their
respective axes of rotation 375A, 375B. With this configuration,
the, rotation of one gear 370A, 370B effects simultaneous and
opposite rotation of the other gear. Thus, the rotation of the
first fence 240A is instantaneously communicated to the second
fence 240B (or vice versa) with each fence being positioned at the
same angle as its counterpart.
[0036] The fences 240A, 240B may also be selectively secured in a
desired position to prevent its pivotal motion and lock the fence
at a desired angle. For example, a latch or clamp mechanism may be
provided that fixes the position of the fence with respect to the
deck 200. FIGS. 5A-5B illustrate a clamp in accordance with an
embodiment of the invention. A lever 500 (e.g., and over-the-center
lever) is pivotally connected to the rod 300. Engaging the lever
500 (e.g., moving the lever from its up (FIG. 5A) position to its
down position (FIG. 5B) draws the rod 300 upward from its normal
position, pulling the fence 240A, 240B downward against the upper
surface of the deck 200 and increasing the friction between the
shoe 310 and the rail 305. This secures the fence 240A, 240B on the
deck 200, preventing its movement along the rail 305. In this way,
when the correct angle has been determined (with the help of the
angle gauge 130 and/or fine adjustment mechanism), the fences 240A,
240B can be locked to the deck to stabilize a workpiece WP when it
is being acted upon by the saw.
[0037] Each fence 240A, 240B, moreover, may be adapted to be
laterally displaced along the surface of the deck 200. Referring to
FIGS. 6A and 6B, each fence 240A, 240B may be a fixed to the deck
200 (via the fence support 217A, 217B) such that the may moves from
a first, inward position (FIG. 6A) to a second, extended position
(FIG. 6B). This assists an operator in cutting a longer workpiece
WP.
[0038] The angle gauge 130 of the present invention is a device
operable to measure the angle between two intersecting surfaces
such as conjoined walls. FIG. 7 is a perspective view of the angle
gauge 130 of FIG. 1 in isolation. In the illustrated embodiment,
the angle gauge 130 includes a housing 710, a first plate or paddle
720A, and a second plate or paddle 720B. Each plate 720A, 720B is
operable to rotate about an axis and move with respect to the
housing 710. A tab (not illustrated) may extend from the housing
that is configured to connect to the notch 230 formed into the
surface of the cutting deck 200, securing the angle gauge 130 to
the base station 110.
[0039] FIG. 8 is an exploded view of the angle gauge 130 of FIG. 7.
In the embodiment illustrated, a first hinge 805A connects the
first plate 720A to a first hinge pin 810A. Similarly, a second
hinge 805B connects the second plate 720B to the hinge pin 810B.
The hinge pin 810A, 810B may be secured to a plate pivot 815 via
channels formed in the plate pivot 815. Specifically, the first
hinge pin 810A is connected to a first channel 820 and second hinge
pin 810B is connected to a second channel 825.
[0040] The first plate 720A and the second plate 720B pivot about
an axis defined by their respective hinge pin 810A, 810B. The first
plate 720A is connected to a first strut 830A, while the second
plate 720B is connected to a second strut 830B. One end of each
strut 830A, 830B connects to its associated plate 720A, 720B at a
strut connection 835A, 835B, respectively. The opposite end of each
strut 830A, 830B, furthermore, is pivotally connected to an
actuator block 840. The actuator block 840 slides within the
housing, and is connected to a stem or rod 845 biased via a biasing
member 850 (e.g., a spring). The biasing member 850 drives stem 845
forward, toward the front of the housing 710 (i.e., in the
direction of the plates 720A, 720B). An actuator or trigger 855
selectively engages and disengages the stem 845 to permit or
prevent the biasing force of the stem to act upon the actuator
block 840. Thus, in the engaged position, the trigger 855 locks the
stem 845, preventing the movement of the stem within the housing
710. Conversely, engaging the trigger 855 releases the stem 845,
permitting the movement of the stem 845 within the housing 710,
driven by the biasing member 850. It is important to note that,
while a trigger is illustrated, the actuator may include other
mechanism such as depressible buttons, etc.
[0041] In operation, the stem 845 controls and limits the movement
of the first and second plates 720A, 720B. Engaging the trigger 855
permits the biasing member 850 to drive the stem 845 toward the
front of the housing 710. Movement of the stem 845, in turn, drives
the actuator block 840 towards the front of the housing 710,
causing a corresponding forward movement of the struts 830A, 830B.
The strut movement rotates the plates 720A, 720B about their
respective hinge pins 810A, 810B. Thus, the plates 720A, 720B may
rotate from a first plate position (e.g., as shown in FIG. 9A) to a
second plate position (e.g., as shown in FIG. 9B) (i.e., the
forward strut movement drives the plates forward). The measured
angle 900 is formed between the first plate 720A and the second
plate 720B. The degree of plate rotation is not particularly
limited to that which is illustrated herein. By way of example,
each plate 720A, 720B may be adapted to pivot approximately
180.degree. (90.degree. clockwise and 90.degree. counterclockwise)
from a 0.degree. reference point. Thus, the angle gauge 130 is
capable of measuring acute angles, 90.degree. angles, and obtuse
angles.
[0042] The plates 720A, 720B are configured contact the corner of
conjoined walls to perform a measurement. In operation, when the
plates 720A, 720B abut intersecting surfaces (e.g., conjoined
walls), the plates 720A, 720B pivot to match the angle between the
wall surfaces, providing the direct measurement of the corner
angle. In this manner, the angle gauge 130 may be used to measure
an interior corner, as well as an exterior corner.
[0043] Operation of the system 100 for forming a miter joint is
explained with reference to FIGS. 10A-10D. To measure the angle
between a pair of conjoined walls W1 and W2, the plates are first
rotated back against the housing 310. Specifically, the actuator
855 is engaged to release the stem 845 and the plates 720A, 720B
are manually pushed back against the housing 710. The angle gauge
130 is positioned within the corner of the walls W1, W2. Using
one-handed operation, the actuator 855 may be once again engaged to
release the stem 845, permitting the biasing action of the spring
to rotate of the plates 720A, 720B toward the walls W1, W2. The
plates 720A, 720B are driven forward by the biasing member 850 (as
described above) until the each plate contacts its respective wall
W1, W2. That is, the plates 720A, 720B pivot about their respective
hinge pin 810A, 810B until the front surfaces of each plate is in
substantially continuous, tight contact with its respective wall
W1, W2 (FIG. 10A). The position of the plates 720A, 720B provides a
direct measurement of the angle existing between the walls W1, W2.
Once the plates are in position, the actuator 855 is disengaged to
secure the plates 720A, 720B at the measured angle 900.
[0044] The angle gauge 130 may then be transferred to the base
station 110. Referring to FIG. 10B, the angle gauge 130 is
positioned on base station. The kerf slot 210 serves as a guide,
orienting the angle gauge onto the deck 200 such that the angle
measured by the plates 720A, 720B is bisected by the kerf slot.
Each fence 240A, 240B is then moved along its associated rail (and
thus its arcuate slot) as described above. The fences 240A, 240B
are driven until the contact their respective plates 720A, 720B.
The fine tune mechanism may be used to provide a continuous, tight
contact between each fence and plate. Once in tight contact, the
fences 240A, 240B are locked via clamp mechanism. In this manner,
the measured angle 900 of the angle gauge 130 is transferred to the
fences on the base station 110.
[0045] The angle gauge 130 is removed, and the workpiece WP is
placed vertically against the fence (i.e., in the same manner the
workpiece connects to its associated wall). Specifically, referring
to FIG. 10D, a first workpiece WP (e.g., a board, molding, etc.)
may then be placed against the first plate 720A such that an end of
the first workpiece WP extends across the kerf slot 210 and, as
such, in the path of the cutting tool blade. A user acts upon the
first workpiece WP using the cutting tool 120. This resulting cut
includes the miter angle directly measured from the first work
surface/wall W1. Similarly, a second workpiece (not illustrated)
may then be placed on the second plate 720B to cut the second
workpiece. The angle of the resulting cut equals the miter angle
associated with the second work surface/wall W2. The cut
workpieces, when placed on their respective walls W1, W2, form a
miter joint with exactly the same miter angles as the walls
W1/W2.
[0046] The above system enables a user to take a direct measurement
of an angle, and transfer that direct measurement to the fences of
a table/miter saw. In contrast to conventional miter saws, the
table does not have to be readjusted between the cutting of a first
corner piece and the second corner piece. The system, then,
eliminates the need to use a measuring device to calculate the
angle, and then convert that measurement to the table saw. In
addition, it simplifies the miter joint forming process by
orienting each corner piece on the table saw in the same manner
each corner piece is oriented on the wall.
[0047] With the above described rail system, the pivot point of the
fence is located under the deck 200, leaving the cutting area open.
This, in turn, allows long pieces of wood to project beyond the
cutting area (and beyond the rear of the base station 110),
permitting cuts to be performed regardless of the length of the
workpiece. In addition, the rail/fence support system permits a
workpiece to be cut in the same orientation it will assume when
installed on a wall.
[0048] While the invention has been described in detail and with
reference to specific embodiments thereof, it will be apparent to
one skilled in the art that various changes and modifications can
be made therein without departing from the spirit and scope
thereof. For example, the base station 110, cutting tool 120, and
measurement tool 130 may be of any size, possess any dimensions,
and be formed from any suitable materials (e.g., wood, plastic,
metal (aluminum), etc. The material from which the deck 200 is
formed may include, but is not limited to, wood, composite
material, metal (e.g., aluminum), plastic, etc. The dimensions of
the deck 200 are not limited to that specifically depicted herein.
The shape and dimensions of the fences 240A, 240B are not
particularly limited to that which is illustrated herein, so long
as they are capable of supporting a workpiece WP and orient it
properly over the kerf slot 210. The clamp mechanism may be
configured such that, when the lever 500 is in its up position, it
interferes with placement of a workpiece WP on the fences and/or
the path of the saw. This serves as a safety mechanism, preventing
a user from using the saw/fences until they are secured in their
locked position. The angle gauge 130 may possess any shape and
dimensions suitable for its described purpose. The angle gauge 130
may further include an onboard calibration display that indicates
the angle that was measured.
[0049] It is to be understood that terms such as "top", "bottom",
"front", "rear", "side", "height", "length", "width", "upper",
"lower", "interior", "exterior", and the like as may be used
herein, merely describe points of reference and do not limit the
present invention to any particular orientation or configuration.
Thus, it is intended that the present invention covers the
modifications and variations of this invention provided they come
within the scope of the appended claims and their equivalents.
* * * * *