Abstract:
A two-part roller support stand has a vertically-adjustable base portion having a plural-point support structure for standing on a ground or floor plane, and a first upper engagement interface, a separate and detachable roller assembly having a roller, a second engagement interface for engaging the first engagement interface, and a plurality of first vertically adjustable feet. The separate roller assembly may be disengaged from the base portion and used, supported on its plurality of adjustable feet, as a stand-alone roller support on such as a table-top or other surface. Additional used for the stand are taught as well

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention is in the field of support apparatus for use by finish carpenters, and pertains more particularly to stands for supporting workpieces during operations with powered miter saws.  
       BACKGROUND OF THE INVENTION  
       [0002]     It is well-known in the woodworking arts that finish carpenters, particularly in home construction, work extensively with miter saws, such as V compound saws, which are also known in the art as chop saws. These are power saws with a rotary saw mechanism mounted on a translatable carriage above a support table, with further mechanisms allowing the saw to be rotated in two to four degrees. These saws are used in every phase of construction, from rough framing to trim moldings, such as baseboard and crown moldings, with angled ends to fit together in inside and outside corners. There are other uses as well.  
         [0003]     Chop saws have a relatively small table surface upon which a length of molding or other material may be placed, typically against a guide called a fence, to be trimmed. Typical moldings, however may be longer than the table, in many cases many times longer than the table. In some cases of new home construction it is not unusual for baseboard molding to be in excess of thirty feet long.  
         [0004]     In operation a chop saw is typically set up on a surface, such as a piece of plywood, on a pair of sawhorses, so the table of the chop saw is at a convenient height for the carpenter. Consider an example with a chop saw having a table 18 inches wide, set up on a surface 48 inches wide. If a piece of molding to be cut is at most a few inches longer than one-half the width of the chop saw table, that piece may be relatively easily and safely held against the fence on the table of the chop saw. If the piece to be cut is, for example two to three feet long, it will need to be supported above the surface of the plywood or other plane surface upon which the chop saw is placed. Most finish carpenters do this by tacking a wooden support to the plywood surface near the chop saw. If a piece is much longer than three feet, then for safe a sure operation the piece has to be supported by a stand of some sort on the ground at some distance from the chop saw. Further, for very long pieces more than one support will be needed.  
         [0005]     There are adjustable roller support stands in the art that stand on the floor (inside) or on the ground (outside), having a relatively wide roller at the top, for placing away from a supported chop saw to support relatively long pieces to be cut. For closer support for shorter pieces, however, a lot of time is taken by carpenters to fabricate makeshift support on the surface supporting the chop saw, to support shorter pieces to be cut.  
         [0006]     What is clearly needed is an adjustable, roller support stand with a removable upper roller assembly, such that the unit may be used as support for long pieces, and the upper roller assembly may be removed from the support stand to provide a roller stand for support on the surface holding the chop saw, for shorter pieces of material.  
       SUMMARY OF THE INVENTION  
       [0007]     In an embodiment of the invention a two-part support stand is provided, comprising a vertically-adjustable base portion having a multiple-point support structure for standing on a ground or floor plane, and a first upper engagement interface, and a separate and detachable assembly having an upper carrier element, a second engagement interface for engaging the first engagement interface, and a plurality of first vertically adjustable feet. The separate detachable assembly, attached to the base portion may be used to support workpieces on the vertically-adjustable base portion, or may be disengaged from the base portion and used, supported on its plurality of adjustable feet, as a stand-alone support for workpieces.  
         [0008]     In one embodiment the plural-point support structure comprises one or more second vertically-adjustable feet. Also in one embodiment the second vertically adjustable feet comprise through holes for use with fasteners in attaching the feet to a surface. In another embodiment the second vertically adjustable feet comprise one or more of pads with rubber-like or fabric underlayers for protection of contacted surfaces, or metal pads with anti-slip features. Also the first vertically adjustable feet may have through holes for use with fasteners in attaching the feet to a surface.  
         [0009]     In some embodiments the first vertically-adjustable feet comprise one or more of pads with rubber-like or fabric underlayers for protection of contacted surfaces or metal pads with anti-slip features. Also in some embodiments the vertically-adjustable base portion comprises one tubing slidably engaging another, and a friction mechanism for restraining the two tubings at a selected height. In still other embodiments the first engagement interface comprises a first length of angle iron having two sides disposed at a right angle at a joined edge, disposed with the joined edge facing upward, and the second engagement interface comprises a second length of angle iron arrayed in the orientation of the first, such that the second may engage the first forming an intimate contact and engagement.  
         [0010]     In some embodiments the upper carrier element is a roller supported between two spaced apart end brackets on one or more shafts with bearings. In other embodiments the detachable roller assembly includes a user-operable brake for engaging the roller to prevent rotation. In still other embodiments the upper carrier element is a flat plate pivotable between two spaced-apart end brackets, and there may be a locking knob for securing the flat plate at a particular angle.  
         [0011]     In another aspect of the invention a support module is provided, comprising end brackets supporting a roller, four adjustable feet, and an engagement interface for engaging a matching interface on an adjustable support stand.  
         [0012]     In yet another aspect of the invention a support module is provided, comprising end brackets supporting a pivotable flat plate, four adjustable feet, and an engagement interface for engaging a matching interface on an adjustable support stand. 
     
    
     BRIEF DESCRIPTION OF THE DRAWING FIGURES  
       [0013]      FIG. 1  is a perspective view of a modular support stand according to an embodiment of the present invention.  
         [0014]      FIG. 2  is an elevation view of the stand of  FIG. 1  in use in an embodiment of the invention.  
         [0015]      FIG. 3  is a magnified view of the stand of  FIGS. 1 and 2  with an upper roller assembly separated from an upper frame component in an embodiment of the present invention.  
         [0016]      FIG. 4  is a perspective view of the frame of the upper roller assembly shown proximate the upper frame assembly in an embodiment of the invention.  
         [0017]      FIG. 5  is an elevation view of a supported chop saw used with a roller assembly according to an embodiment of the present invention.  
         [0018]      FIG. 6  is a partial section through upper roller assembly  109  to show detail of a brake assembly in one embodiment of the invention.  
         [0019]      FIG. 7   a  illustrates an embodiment of the invention comprising a unit the inventor terms a silent partner support.  
         [0020]      FIG. 7   b  is a section view taken along line  7   b - 7   b  of  FIG. 7   a.    
         [0021]      FIG. 8  illustrates yet another embodiment of the invention, useful for supporting utility elements. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0022]      FIG. 1  is a perspective view of a modular support stand  101  according to an embodiment of the present invention. Stand  101  has a first lower frame component  102  consisting of a tubular portion  113  and a cross-piece  103  joined to tubular portion  113  by such as welding or brazing in this embodiment. Cross-piece  103  has adjustable support feet  107  for partially supporting the stand. A second lower frame component  104  joins as a separable entity to first frame component  102  by means of a hand knob  105  having a threaded post (not seen) that engages a nut (also not seen) within tubing of component  104 . In preferred embodiments frame component  104  pivots in a hinged arrangement on component  102 , such that components  102  and  104  may lie adjacent for transport and shipping, and component  104  may be extended to place the stand in operation, with component  104  secured in position by engaging and tightening knob  105 .  
         [0023]     Frame component  104  also has a cross-piece  106  with two adjustable support feet  107 , one at each end as for cross-piece  103  of component  102 . With component  104  assembled to component  102  a sturdy and stable base is formed having four adjustable feet ( 107 ) for supporting all of the other parts of the stand. Also in preferred embodiments feet  107  may have through holes  116  in one or more of feet  107  for attaching the feet to such as subflooring at a construction site, to maintain the stand in rigid position during use. In some embodiment the ability to attach to the subflooring may be provided at any two of the feet, and in some cases may be provided by another mechanism, such as a bracket  117  welded to cross piece  103  or crosspiece  106 .  
         [0024]     An upper frame component  108  comprises a square tubular portion  112  joined to an upper roller assembly  109  in a manner to be described below with aid of further figures. In an embodiment of the invention roller assembly  109  is modular and quickly and easily removable from upper frame  108 . Tubular portion  112  is smaller than portion  113  of component  102  such that portion  112  may slide within portion  113  so the height of roller assembly  109  may be adjusted above the ground level upon which feet  107  reside. A knob  114  engages through a nut (not shown) welded to portion  113 , such that a shaft may be brought to bear on portion  112  to fix the height once adjusted.  
         [0025]      FIG. 2  is an elevation view of the stand of  FIG. 1  in use in an embodiment of the invention. In this example chop saw  201  is supported on a piece of plywood  202  in turn supported on two saw horses  203  on a floor or ground surface. The skilled artisan will recognize that there are many models and varieties of such saws in the art, and the representation of chop saw  201  is meant to be exemplary and inclusive. The skilled artisan will also recognize that the chop saw may be supported on tables other than the piece of plywood on saw horses, but the arrangement shown is a typical mode of use on a job site where it is necessary to trim materials such as moldings for finish carpentry work.  
         [0026]     Moldings of all types and of many different lengths may need to be beveled and trimmed on such a job site. Baseboard moldings, for example, may be quite long, or relatively short. Molding  204  represented in  FIG. 2  is of a length sufficient that outboard support is needed to hold the molding level so trim cuts may be accurately, efficiently and safely made. For molding much longer additional supports may be needed as well.  
         [0027]     It was briefly mentioned above that roller assembly  109  may be quickly and easily removed from upper frame  108  in an embodiment of the invention. In the arrangement shown it is not necessary to do so, and in fact such stands exit in the art wherein the roller assembly is an integral part of the overall stand assembly, and these prior art stands are commonly used for support of long pieces to be trimmed.  
         [0028]      FIG. 3  is a magnified view of upper roller assembly  109  and an upper part of frame component  108  in which roller assembly  109  has been removed from frame component  108 . Roller assembly  109  has been partially sectioned to illustrate additional detail of construction in this particular embodiment. In frame component  108  a short piece of angle iron  115  is welded to tubular portion  112  such that the apex of the angle of the angle iron is directed upward forming a triangle with a horizontal base. Framing of modular roller assembly  109  also comprises an angle iron  301  in the same orientation as angle iron  115  of upper frame  108 , wherein angle iron  301  is welded between two end brackets  302 . The end brackets  302  form spaced-apart vertical surfaces between which roller  110  is mounted on a shaft with bearings. The bearings can be of any one of several different types, such as roller bearings of journal bearings to provide for easy rotation of the roller. The upper roller assembly also comprises four adjustable feet  111  similar to adjustable feet  107  used on the lower support elements.  
         [0029]     A portion of  FIG. 4  is a perspective view of the frame of upper roller assembly  109 , composed of angle iron  301  and the two end brackets  302 , shown proximate the upper frame assembly  108  as in  FIG. 3 , but without roller  110  and adjustable feet  111 . Angle iron  301  has been cut away to show a triangular opening  402  that is formed at each end by welding the angle iron to horizontal flange portions of end brackets  302 . This opening in one embodiment of the invention is important to secure the upper roller assembly  109  to the upper frame assembly  108 .  
         [0030]     In this embodiment length L of angle iron  115  is somewhat greater than length X of angle iron  301 . For example, if X is 8 inches, L may be 8.5 inches. So roller assembly  109  will not mate with frame assembly  108  by simple vertical placement. In this embodiment a portion of length L of angle iron  115  on each end is machined to fit easily into triangular openings  402  on each end of assembly  109 . Joining of the two is accomplished by engaging one end of angle iron  115  in one of openings  402  far enough that angle iron  301  may intimately rest on angle iron  115 . Then the roller assembly is moved so both ends of angle iron  115  engage openings  402  at each of the end brackets.  
         [0031]     The skilled artisan will recognize that the joining arrangement described above is but one example of how the two assemblies may be easily and quickly joined, and may be expected to stay joined in use. There are a variety of other ways this joining may be accomplished, such as by plate-to-plate contact and securing with conventional fasteners, such as bolts and nuts.  
         [0032]      FIG. 5  is an elevation view of a supported chop saw being used with a relatively short piece of molding  501  to be cut. Molding  501  is too long to be cut reliably unsupported from table  202 , but too short to be supported by the integrated roller stand  101  as shown in  FIG. 2 . In this case upper roller assembly  108  has been disengaged from stand  101  and placed on table  202  supported by feet  111 , which have been pre-adjusted to provide the roller at the correct height, that is at the table height of chop saw  201 . The idea in every case is that a molding or other piece to be cut should never be unsupported such that if the operator lets go, the molding will tip up on the chop saw table. For this use, there may be through holes in one or more of feet  11 , just as described above for feet  107 , so the upper roller assembly may be secured to the chop saw table by such as screws or other conventional fasteners.  
         [0033]     Roller  110  in the roller assembly may be metal, or may be fabricated from a polymer material, such as a ultra-high-molecular-weight (UHMW) polymer. The bearings that carry the roller on a shaft or shafts supported by end brackets  302  of roller assembly  109  may be in some cases journal bearings, or may be ball bearings. Adjustable feet  111  may be mounted to be adjustable in any of several ways. The threaded post arrangement shown with nuts is but one example.  
         [0034]     In one embodiment there may be an additional feature associated with upper roller assembly  109  to aid in a particular situation in operation. The particular situation is as follows: when one has a piece of material to be cut on a chop saw, with one end supported, as in either of  FIG. 2  or  FIG. 5 , the purpose is always to provide a trimmed piece for a specific purpose; so one of the resulting two pieces is the trimmed piece, and the other is surplus, either to be discarded or reused. In some cases the finished piece will be that to the left side of the blade, and in some cases the finished piece will be that to the right side of the blade, depending on the angle and the nature of the cut to be made.  
         [0035]     Experience has shown that it is best to hold the side that will result in the finished piece with one hand securely until the cut is finished. The other hand has to operate the chop saw carriage. If the finished piece is on the side with the support stand, there is no problem, because that side will be held with one hand. If the finished piece is on the right, however, then the piece on the left, with additional length supported by the roller stand or upper roller assembly on the chop saw table, then there is a potentially bad situation. If there is sufficient overhang, placing too much weight on the side of the support stand roller away from the chop saw table, then, at the point in time that the cut is finished the piece not held may tip up and roll away, striking the floor or some other object. This at the minimum can mean an extra cut to be made, or a piece not further usable.  
         [0036]     As an answer to this situation, in one embodiment a friction brake is provided to temporarily lock roller  10  from rolling.  FIG. 6  is a partial section through upper roller assembly  109  to show some detail of one such friction brake. In this example a tapered lever  601  is supported on two pins  602  engaged in a slot  603  cut in end piece  302 . The slot is provided in a position and of a length that a user may withdraw lever  601  along the slot so no engagement is made between roller  110  and the lever, which may be further supported by angle iron  115 , or the user may move the lever to wedge between roller  110  and angle iron  115 , to effectively prevent the roller from turning. The lever, at least at the surface where it will engage the roller, may be made of a plastic material or a flexible, rubber-like material to better wedge and lock the roller.  
         [0037]     Now, in the particular situation described above, when there is a chance that a piece not securely held may tip up and roll away at the finish of a cut, the user may first lock the roller, providing ample time after a cut is finished to catch the piece that might otherwise get away.  
         [0038]     Chop saws may be used inside houses under construction or in houses where remodeling is being done, or may be used out-of-doors as well. For this reason adjustable feet  111  for the roller assembly and  107  for the roller stand may be of several different types. In one case the pads may be metal with anti-slip features, such as pointed protrusions or corrugation, for use perhaps on dirt surfaces. In other cases the pads may have a rubber-like or a fabric (such as felt) pad on the undersurface to avoid damaging such as tile or hardwood floors where a stand may need to be used. In many cases there may be openings through the feet for fasteners, such as bolts or screws, for fastening to such as subflooring.  
         [0039]     In still another embodiment of the present invention the lower frame ( 102  of  FIG. 1 ) may be used as a support stand for a variety of purposes other than supporting an upper roller assembly.  FIG. 7   a  illustrates an embodiment comprising a unit the inventor terms a silent partner support. In this embodiment upper assembly  109  has no roller, but instead a pivotable flat plate  701 , made pivotable by a pivot shaft  702  fastened to the underside of plate  701 .  FIG. 7   b  is a section view of the plate and pivot shaft taken along line  7   b - 7   b  of  FIG. 7   a . As shown in  FIG. 7   b  the shaft may be secured to the plate in a number of ways, such as by one or more brackets  703 , by welding, or in other ways. The shaft may be one shaft greater in length than the plate, or there may be two shafts in axial alignment, one at either end of the plate.  
         [0040]     At one or both ends shaft  702  has male threads, and a hand knob with a female thread may be used at one or both ends to secure plate  701  in the assembly so it does not rotate on the shaft. The purpose of the repositionable flat plate on the adjustable support stand is as a stationary aid for supporting material without movement during installation or production.  
         [0041]     It is not intended that the plate and pivot shaft be easily removable from the assembly  109 . Rather it is the entire assembly that is removable, so it may be used in this mode as a stationary support on the adjustable stand  102 / 108 , or on a saw table or other surface, A skilled artisan will be aware that the plate may vary in width and that there are a number of other changes that might be made without departing from the spirit and scope of the invention.  
         [0042]      FIG. 8  illustrates an embodiment of the invention useful for supporting other useful elements and apparatus not thus far described. Apparatus 800 is based on a length of angle iron  801  synonymous with angle  301  of assembly  109  in  FIG. 3 . Angle  801  has a short piece of flat stock  806  welded to the bottom of the angle to create a pocket  805  at each end. It is pocket  805  that provides the necessary sockets for attaching assembly  800  to angle  115  of upper support assembly  108  (see  FIG. 3 ). Angle  801  has through holes  804  strategically placed, and shaped bars  802  attached also at strategic locations. Bars  802  may be welded in place, or bolted, or fastened by some other conventional method. Bars  802  have threaded studs  803  attached for use in mounting other units to the stand. Many sorts of utility elements, such as florescent light fixtures, halogen fixtures and the like may be attached to assembly  800  in various embodiments.  
         [0043]     The skilled artisan will be aware that many features of the integrated roller stand and utility stand described in enabling detail in various embodiments above may be altered from the examples illustrated and described in this disclosure, without departing from the spirit and scope of the invention. For example, there are a variety of ways the vertical adjustability of the integrated roller stand may be accomplished. There are also many different materials that may be used. In addition, the base support may be accomplished in different ways. There are similarly many other alterations that fall within the spirit and scope of the invention, which should be accorded the breadth of the claims to follow.