Abstract:
A woodworking station is provided, in which cutting heads and cutting bits, e.g. routers, small-bodied rotary tools, plunge routers, and others, are either permanently or interchangeably positioned with respect to a tiltable and rotatable cutting table, such that the operator&#39;s hands are free to manipulate the wood being worked. The cutting heads can be raised and lowered by hand controls, or by a foot-controlled electric motor. Self-contained blowers are also included, providing for continuous and simultaneous sawdust removal. Directional lighting is also provided which directs light primarily to the cutting table and away from the operator&#39;s face.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates generally to routers, rotary tools, and other cutting tools and accessories used for woodworking, and the manner and environment in which they are utilized. 
     2. Description of the Prior Art 
     There are router attachment devices designed for extending the use of a router and other cutting heads. Typical of these is U.S. Pat. No. 5,311,914 issued to Stornetta on May 17, 1994. 
     Another patent was issued to Johnson on Jan. 24, 1995 as U.S. Pat. No. 5,383,503. Yet another U.S. Pat. No. 5,617,909 was issued to Duginske on Apr. 8, 1997 and still yet another was issued on Apr. 14, 1998 to Sugita as U.S. Pat. No. 5,738,470. 
     Another patent was issued to Kopras on May 11, 1999 as U.S. Pat. No. 5,90,080. 
     A router dust hood has a sub base which attaches to the base plate of a router. A dust hood slides over the motor and is coupled to the sub base. The handles of the router are taken off and mounted on to the hood. A top rubber casing slides over the motor and is coupled to the top of the dust hood. A vacuum is coupled to the dust hood for the removal of chips and dust from the work area. The sub base raises the router off the work surface allowing more air volume around the router bit to aid in the quickened removal of dust and chips from the work area into the vacuum. The sub base is circularly designed, with an outer lip, allowing an operator to guide the router on a template. 
     Apparatus for guiding the movement of a hand held router relative to a workpiece comprises a support forming an upwardly facing base adapted to underlie and support a workpiece to be routed. A plurality of parallel guide posts extend upwardly from the support and carry a rigid frame having an open central portion. The frame is mounted on the guide posts for guided sliding movement toward and away from the base to overlie a workpiece supported on the base. Springs bias the frame away from the base and clamps act to overcome the bias and clamp the frame into engagement with the uppermost surface of a workpiece supported on the base. A router guide template is removably connected in the open central portion of the rigid frame at a location to substantially engage the uppermost surface of a workpiece support on the base when the frame is clamped into engagement therewith. 
     A woodworking machinery jig and fixture system includes a track which is attached to a separate plywood fence, auxiliary table or other workpiece support of woodworking machinery such as a table saw, a band saw, radial arm saw, miter saw, a drill press or a router table. A flip stop and an optional microadjuster mount to a T-shaped slot in the track. An angle bracket is also provided for making right angle connections of track to track or track to support. A location stop records the position of a track relative to a flip stop or other jig or fixture and a circle jig can be used in the track to cut circles. A miter guide, optionally having a fixed head, has a longitudinally adjustable auxiliary fence and a miter bar with an anti-play feature in which a bearing is adjusted to slide on the side of a table top slot in which the bar is received. A guideway for the miter guide has a concave bottom wall which adjustably flexes to tighten the guideway around a miter guide bar. 
     In a guide device for cutting a groove of this invention, a rectilinear guide member ( 10 ) comprises a pair of guide members ( 11 ,  12 ), where the opening width (W 1 , W 2 ) of an opening ( 26 ) defined between the guide members ( 11 ,  12 ) is set to be the same as the diameter of a rotary bit of a router ( 22 ). A dado ( 2 ) having a width that is the same as the thickness of a board to be used as a shelf is formed by operating the router ( 22 ) with a scrap piece of that board ( 3   a ) inserted between the guide members ( 11 ,  12 ) to get an accurately cut dado. 
     A detachable battery pack is connectable to hand-held power tools, such as spiral cutting tools, in which cuts are made by positioning the axis of the cutting tool motor housing perpendicular to a workpiece surface, and moving a cutting tool bit through the workpiece in a direction perpendicular to the axis of the bit to remove material from the workpiece. The battery pack allows the cutting tool to be utilized without an electric cord and without the need of a power source near-by, thereby increasing maneuverability, safety, and range of use. The battery pack is connected to the motor housing of the power tool by being received by a receptacle. The receptacle is preferably formed to include one or more storage compartments therein, accessible through apertures in the receptacle for storage of additional cutting tool bits. A sliding door on the receptacle may be provided to allow access to the storage compartments, and to close the compartments to secure items stored therein during operation of the cutting tool. The receptacle extends outwardly beyond the motor housing over a handle so that the weight of the battery pack is centered over the handle. 
     A drill press attachment device is provided by Dremel Tools, and is referred to as the Model #212. It appears to be very small and particularly configured for a small-bodied rotary tool, with a hand crank for lowering and raising the tool on a single shaft over a cutting table. 
     While these woodworking devices may be suitable for the purposes for which they were designed, they would not be as suitable for the purposes of the present invention, as hereinafter described. 
     SUMMARY OF THE PRESENT INVENTION 
     A primary object of the present invention is to provide a woodworking station that will overcome the shortcomings of prior art devices. 
     Another object of the present invention is to provide a woodworking station that can effectively position and utilize a cutting head, e.g. a router, such that the cutting head is stationary while the wood is moved by the operator. 
     A further object of the present invention is provide a woodworking station which raises or lowers the cutting head in response to a foot control, thus leaving the operator&#39;s hands free for wood handling. 
     Another object of the present invention is to provide such a woodworking station that includes blower devices that are optimally located and conveniently controlled, such that sawdust is continuously removed from the cutting bit area. 
     Yet another object of the present invention is to provide a fixed and accurately positioned router that can start a new cut, by lowering the router onto the wood, thus negating the need for pre-drilling a hole, as is the case with a scroll saw. 
     Yet another object of the present invention is to provide a woodworking station that allows various hand held cutting heads, e.g. routers, small-bodied rotary tools, and others, to be secured and optimally positioned with respect to the cutting table, the hand held tools having large variations in body width. 
     Still yet another object of the present invention is to provide a woodworking station that includes a lighted cutting table, with such lighting being optimally placed and controlled for maximum coverage of the cutting table, the amount of light shining toward the operator&#39;s face being minimized. 
     Still yet another object of the present invention is to provide a woodworking station in which the cutting head approach to the cutting table is optimized by the cutting table&#39;s ability to both tilt and rotate in a horizontal plane. 
     Additional objects of the present invention will appear as the description proceeds. 
     The present invention overcomes the shortcomings of the prior art by providing a woodworking station in which cutting heads and cutting bits, e.g. routers, small-bodied rotary tools, plunge routers, and others, are either permanently or interchangeably positioned with respect to a tiltable and rotatable cutting table, such that the operator&#39;s hands are free to manipulate the wood being worked. The cutting heads can be raised and lowered by hand controls, or by a foot-controlled electric motor. Self-contained blowers are also included, providing for continuous and simultaneous sawdust removal. Directional lighting is provided which directs light primarily to the cutting table and away from the operator&#39;s face. 
     The foregoing and other objects and advantages will appear from the description to follow. In the description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration, specific embodiments in which the invention may be practiced. These embodiments will be described in sufficient detail to enable those skilled in the art to practice the invention, and it is to be understood that other embodiments may be utilized and that structural changes may be made without departing from the scope of the invention. In the accompanying drawings, like reference characters designate the same or similar parts throughout the several views. 
     The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is best defined by the appended claims. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In order that the invention may be more fully understood, it will now be described, by way of example, with reference to the accompanying drawings in which: 
     FIG. 1 is an oblique right side view of the woodworking station of the present invention, being supported by a table. 
     FIG. 2 is an oblique right side view of the woodworking station of the present invention, emphasizing the permanently affixed cutting head and operator controls. 
     FIG. 3 is an oblique right side view of the woodworking station of the present invention, illustrating the lighting pattern. 
     FIG. 4 is an oblique right side view of the woodworking station of the present invention, with a cutaway of the cutting table, emphasizing the cutting table and its tilt and rotation mechanisms, and interchangeable inserts. 
     FIG. 5 is an oblique right side view of the woodworking station of the present invention, emphasizing the vertical adjustability of the cutting head. 
     FIG. 6 is an oblique right side view of a wood workpiece being cut by the cutting bit, without a pre-drilled hole. 
     FIG. 7 is an oblique right side view of the woodworking station of the present invention, emphasizing the universal mount and manual control arm. 
     FIG. 8 is an oblique right side view of the woodworking station of the present invention, emphasizing the standard router approach to the universal mount. 
     FIG. 9 is an oblique right side view of the woodworking station of the present invention, illustrating the standard router position in the universal mount. 
     FIG. 10 is an oblique right side view of the woodworking station of the present invention, emphasizing the components of the interchangeable cutting head embodiment, with the standard router in place. 
     FIG. 11 is an oblique right side view of the woodworking station of the present invention, illustrating the vertical adjustability of the standard router. 
     FIG. 12 is an oblique right side view of the woodworking station of the present invention, illustrating the small-bodied rotary tool approach to the universal mount. 
     FIG. 13 is a cutaway right side view of the woodworking station of the present invention, illustrating some of the internal components for the embodiment shown, with the cutting head in a raised position. 
     FIG. 14 is a cutaway right side view of the woodworking station of the present invention, illustrating some of the internal components for the embodiment shown, with the cutting head in a lowered position. 
     FIG. 15 is a cutaway right side view of the woodworking station of the present invention, illustrating some of the internal components for the embodiment shown, with the universal mount in a raised position. 
     FIG. 16 is a cutaway right side view of the woodworking station of the present invention, illustrating some of the internal components for the embodiment shown, with the universal mount in a lowered position. 
     FIG. 17 is an oblique right side view of the woodworking station of the present invention, illustrating the blower hose position with respect to the standard router. 
     FIG. 18 is an oblique right side view of the woodworking station of the present invention, illustrating the vertical adjustment knob. 
     FIG. 19 is an oblique view of a portion of the control arm and the control arm shaft wing. 
     FIG. 20 is a cutaway view of a portion of the control arm and the stop gear, illustrating the control arm shaft wing within the internal threads of the stop gear. 
    
    
     DESCRIPTION OF THE REFERENCED NUMERALS 
     Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, the Figures illustrate the woodworking station of the present invention. With regard to the reference numerals used, the following numbering is used throughout the various drawing figures. 
       10  woodworking station of the present invention 
       12  base 
       13  wood workpiece 
       14  tower 
       16  extension member 
       18  permanently affixed cutting head 
       19  cutting bit 
       20  router 
       22  small-bodied rotary tool 
       30  universal mount 
       32  support member 
       34  grasping member 
       36  grasping member side 
       38  grasping member side 
       40  grasping member width adjustment screw 
       42  grasping member positioning screw 
       44  setscrew and brace combination 
       46  setscrew and brace combination 
       48  router power chord 
       50  small-bodied rotary tool power chord 
       52  extension member hole 
       60  cutting table 
       61  cutting table hole 
       62  tilt mechanism 
       64  tilt mechanism setscrew 
       66  pedestal 
       67  cutting hole interchangeable insert 
       68  cutting hole interchangeable insert 
       72  pinion gear 
       74  rack gear 
       76  spur gear 
       78  control arm 
       80  control arm shaft wing 
       82  control arm shaft 
       84  stop gear 
       86  knob 
       90  electric motor 
       92  electric motor foot control 
       100  blower motor 
       102  blower motor discharge 
       104  sawdust 
       110  blower motor 
       112  hose 
       120  electric light 
       122  electric light 
       124  light beams 
       130  permanently affixed cutting head power switch 
       132  permanently affixed cutting head speed control 
       134  blower power switch 
       136  blower speed control 
       138  light switch 
       140  wiring and wiring harnesses 
       142  electric junction box 
       144  power chord 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Turning now descriptively to the drawings, in which similar reference characters denote similar elements throughout the several views, FIGS. 1 through 20 illustrate the woodworking station of the present invention indicated generally by the numeral  10 . 
     The woodworking station  10  is shown in FIG. 1, and a representative wood workpiece  11  is shown in FIG.  6 . The woodworking station  10  is a device which is optimally configured and equipped for woodworking activities utilizing a cutting head, e.g. a router or small-bodied rotary tools having body portions with diameters as small as {fraction (1/2 )}inches. 
     The device  10  has a base  12  for positioning the device  10  on a substantially horizontal surface such as a table, as illustrated in FIG. 1. A tower  14  extends from the base  12  in a primarily vertical direction. An extension member  16  extends from the tower  14 . A cutting head  18  is permanently affixed to the extension member  16  in the embodiments shown in FIGS. 1-6,  13 - 14 , the cutting head  18  having a removable cutting bit  19 . In an alternate embodiment, a router  20  and a small-bodied rotary tool  22  are removably secured beneath the extension member  16  by the use of the universal mount  30 , as shown in FIGS.  8 - 11 , 17  and FIG. 12, respectively. 
     The universal mount  30  is attached to a support member  32 , which is attached to the extension member  16 . As shown in FIGS.  7 - 8 , 12 , 15 - 16 , the support member  32  is rigid and extends in a generally downward direction. At least one grasping member  34  is attached to the support member  32 , and is positioned to receive various cutting heads, e.g. the router  20  and the small-bodied rotary tool  22 , as shown in FIG.  8  and FIG. 12, respectively. In this embodiment, the grasping member  34  is generally “U” shaped, with sides  36  and  38  being expandable by rotation of the width adjustment screw  40 . In other embodiments (not shown), the grasping member sides  36 , 38  are curved in a “C” shape. To optimize the grasping function of the grasping member  34 , a grasping member positioning screw  42  is provided, which allows positioning of the grasping member  34  along the support member  32 , which in turn allows the grasping member  34  to encompass the body of the router  20  or small-bodied rotary tool  22  at the optimum location on their respective bodies. 
     The grasping function is even further optimized by positioning the grasping member  34  on the support member  32  such that the router  20  or small bodied rotary tool  22  abuts the extension member  16 . This provides support against lateral movement of the router  20  or small-bodied rotary tool  22 . Such lateral movement can be resisted even further by a recess (not shown) in the underside of the extension member  16 , the router  20  or small-bodied rotary tool  22  contacting the extension member  16  in such recess. 
     The grasping function can also be enhanced or independently accomplished by the addition of opposing setscrew and brace combinations  44 , 46  on the grasping member sides  36 , 38 , as shown in FIGS.  7 - 10 , 12 , 15 - 17 . Rotation of such setscrews and braces  44 , 46  causes the router  20  or small-bodied rotary tool  22  to be squeezed. By carefully adjusting such setscrew and brace combinations  44 , 46 , an enhanced vertical alignment of the router  20  or small-bodied rotary tool  22  can also be achieved. The curved brace portions of the setscrew and brace combinations  44 , 46  are preferred, but optional. 
     The power chords  48 , 50  for the router  20  and small-bodied rotary tool  22  are shown in FIGS.  8 - 10 , 12 , 17 . In the case of the power chord  50  for the small-bodied rotary tool  22 , the extension member  16  can be provided with a hole  52  sized to allow passage of such power chord  50  through the extension member  16 . 
     A cutting table  60  is provided which has cutting table hole  61 , which allows the passage of the various cutting bits  19 . The cutting table  60  is mounted on a tilt mechanism  62 . The amount of tilt is adjusted by loosening tilt mechanism setscrew  64 , moving the table  60 , and re-tightening the setscrew  64 . The tilt mechanism  62  is rotatably mounted on a pedestal  66 , the pedestal  66  being attached to the base  12 . The rotation of the table  60  on the pedestal  66  is in a plane, which is substantially horizontal to the base  12 . A table hole  61  is provided. 
     A rack and pinion gear combination is within the tower  14 , the pinion gear  72  being rotatably attached to the tower  14 , while the rack gear  74  is slidably positioned for movement along the tower  14  in a substantially vertical direction. The pinion gear  72  is rotated by a spur gear  76 , which is attached to the tower  14 . A control arm  78  extends into the tower  14  and is attached to the spur gear  76 , such that movement of the control arm  78  rotates the spur gear  76 , which rotates the pinion gear  72 , which, in turn, slides the rack gear  74 . The extension member  16  attaches to the rack gear  74  and is thus moved with respect to the tower  14  as the rack gear  74  moves. FIGS. 13-16 show one or more of the pinion gear  72 , the rack gear  74 , the spur gear  76 , and the control arm  78 , however, the illustrations of the relative sizes of such components are not necessarily to scale. In particular, the pinion gear  72  and spur gear  76  can be sized, relative to the rack gear  74 , such that rotation of the pinion gear  72  by the loaded rack gear  74  is effectively resisted. Such resistance can be assisted by allowing the loaded extension member  16  to slightly push the rack gear  74  into the pinion gear  72 . 
     Such resistance can also be accomplished by a mechanical stop, which locks the control arm  78  when into its intended position. In one embodiment, as shown in FIGS. 19-20, the stop is at least one wing  80  rising from the shaft  82  of the control arm  78 . The control arm  78  can be pulled from a first to a second position, as shown in FIGS.  9 - 10 , 17 , this movement to be distinguished from the above-described rotation of the control arm  78 . In this second position, the control arm shaft  82  extrudes farther from the tower  14 , although the spur gear  76  remains in engagement with the pinion gear  72  in either position. When the control arm shaft  82  is so pulled, it is pulled through, and the control arm shaft wing  80  is pulled into engagement with, a stop gear  84 , which has internal teeth and is affixed to the tower  14 . The internal teeth on the stop gear  84  are sized to closely receive the control arm shaft wing  80 . When the control arm  78  is returned to the first position, the control arm shaft  82  is pushed back into the tower  14 , and the control arm shaft wing  80  disengages from the stop gear  84 . In an additional embodiment, the control arm shaft wing  80  can be replaced with a full set of gear teeth (not shown) to correspond with the internal teeth of stop gear  84 . In yet another embodiment, the control arm  78  is replaced by a knob  86  sized for grasping by hand. The knob  86  is directly attached to the foregoing control arm shaft  82 , which allows a substantially straight pull on the control arm shaft  82 , for purposes of pulling the control arm shaft wing  80  into engagement with the stop gear  84 . 
     In an alternative embodiment (not shown) the control arm shaft  82  includes a worm gear which rotates a spur gear having a shaft. The spur gear shaft includes a worm gear and is aligned with the pinion gear  72 , or a parallel gear affixed to the pinion gear  72 , such that rotation of the spur gear shaft rotates the pinion gear  72 . The presence of a worm gear in the control arm  78  to pinion gear  72  gear combination, further resists movement of the pinion gear  72  by the rack gear  74 . 
     In an alternative embodiment (not shown) the control arm shaft  82  attaches directly to the pinion gear  72 , and the spur gear  76  is omitted. 
     In an additional embodiment, shown in FIGS.  1 - 6 , 13 - 14 , the spur gear  76  is rotated by an electric motor  90 . A foot control  92  is provided to control the electric motor  90 , allowing the extension member  16  to be raised and lowered without the use of the operator&#39;s hands. 
     A blower motor  100  is provided as shown in FIGS. 15-16. The blower motor  100  is contained within the base  12 , and has a blower discharge  102  positioned on the tower  14 , for blowing sawdust  104  off the cutting table  60 . In other embodiments (not shown) the blower motor  100  may be positioned within the tower  14 , the base  12 , or the extension member  16 . In other embodiments a blower motor  110  is attached to the extension arm  16  and has an air discharge hose  112 , as shown in FIGS.  1 - 4 , 13 - 14 , 17 . FIGS.  1 - 5 , 13 - 14 , 17  depict embodiments where the hose  112  is clamped to the permanently affixed cutting head  18 , or the universal mount  30 , and is proximate the permanently affixed cutting head  18  or the router  20 , the hose  112  being shaped such that it discharges air in the immediate vicinity of the table hole  61 . The hose  112  can be unclamped and directed to other portions of the cutting table  60 . Embodiments are also provided (not shown) in which blower air is selectably discharged from either the tower  14  or a hose. 
     FIGS. 2-3,  10 ,  12 - 15  reference and illustrate the lights  120 , 122  which are positioned within the tower  14 . FIG. 3, in particular, shows the directional character of the light beams  124  when the lights  120 , 122  are so positioned. This positioning minimizes the light in the eyes of the operator and maximizes the coverage of the cutting table  60 . In an additional embodiment (not shown), one or more lights can be positioned lower on the tower  14 , which minimizes the shadow of the cutting head on the workpiece. Such lights can be in place of, or in addition to, lights  120 , 122 . 
     Conveniently placed controls are provided for the applicable features of all embodiments. For example, FIG. 2 illustrates the positions of a power switch  130 , and a speed control  132 , for the permanently affixed cutting head  18 . Similarly, a blower power switch  134 , a blower speed control  136 , and a light switch  138  are also provided. Representative wiring and wiring harnesses  140  for the controls and the related electrical devices, along with an available location for the electric junction box  142 , and power chord  144 , are shown in FIGS. 12-16. 
     It is anticipated that cast iron will be utilized for the most part in the construction of the primary structural components of the device  10 , although steel and other high strength materials may be substituted. The various gears  72 , 74 , 76 , 84  can be made from annealed carbon steel, bar stock, forgings, castings, or alloy steel. 
     It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of methods differing from the type described above. 
     While certain novel features of this invention have been shown and described and are pointed out in the annexed claims, it is not intended to be limited to the details above, since it will be understood that various omissions, modifications, substitutions and changes in the forms and details of the device illustrated and in its operation can be made by those skilled in the art without departing in any way from the spirit of the present invention. 
     Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.