Abstract:
A saw system in one embodiment includes a base, a work support surface member supported by the base and including a work piece support surface defining a horizontal work piece support plane, and a plurality of wheels, each of the plurality of wheels engaged with at least one of the base and the work support surface member, wherein none of the plurality of wheels is attached to either the base or the work support surface member.

Description:
FIELD OF THE INVENTION 
       [0001]    This patent relates generally to the field of devices used to cut tiles and other hard materials, including devices with movable work support surfaces. 
       BACKGROUND 
       [0002]    Tile saws are widely used for cutting hard materials such as bricks and tiles. Tile saw systems typically include a power head assembly, a table, a base for supporting the table and a water tray located under the base. The system is configured to apply a stream of water to a blade held within the power head assembly. The water flows over the work piece and is collected in the water tray. The water is thus used to cool the blade and the work piece. Additionally, debris formed by cutting the work piece is entrapped in the water. 
         [0003]    In some tile saw systems, the table upon which a work piece is supported is movable with respect to the power head assembly. This allows for increased control over the cut since the work piece can be secured to the table at a desired orientation. In such moving table systems, a rail structure may be provided on the base. The rail structure is engaged by rollers attached to the table. By applying force to the table, the rollers roll along the rail system allowing the work piece to be brought into contact with the blade in the power head assembly. 
         [0004]    While rail and roller system can be very effective in increasing the accuracy of cuts, the rail and roller system can significantly increase the bulk of the tile saw. For example, when cutting a twenty-four inch tile, the table must move at least 24 inches in order to pass the entire tile past the blade. If the tile is to be cut on a diagonal, then the work support surface must be capable of moving about 34 inches. A work support surface of nearly three feet in length is difficult to manipulate. 
         [0005]    Moreover, a work support surface of increased length makes storage of the tile saw more inconvenient. Furthermore, users frequently desire to set up a tile saw in proximity to the location at which the tiles are to be installed. As the bulk of the tile saw is increased, the ability to easily transport and locate the tile saw at a work area is diminished. 
         [0006]    What is needed is a saw system with a table assembly which can be used to guide movement of a work piece positioned thereon. What is further needed is a table assembly which allows a user to support and move larger work pieces without excessively increasing the footprint of the saw system. 
       SUMMARY 
       [0007]    In accordance with one embodiment of the disclosure, a saw system includes a base, a work support surface member supported by the base and including a work piece support surface defining a horizontal work piece support plane, and a plurality of wheels, each of the plurality of wheels engaged with at least one of the base and the work support surface member, wherein none of the plurality of wheels is attached to either the base or the work support surface member. 
         [0008]    In another embodiment, a saw system includes a table assembly with a base, a first wheel engaged with the base, a work support surface member defining a horizontal work piece support plane and movable with respect to the base along a cutting axis, and a second wheel engaged with the work support surface member, wherein the first wheel is not attached to the base or the work support surface member, the second wheel is not attached to the base or the work support surface member, and the first wheel and the second wheel are movable with respect to the base and the work support surface member along the cutting axis. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  depicts a perspective view of a tile saw system including a table assembly in accordance with principles of the present invention; 
           [0010]      FIG. 2  depicts a splayed apart perspective view of the table assembly of  FIG. 1 ; 
           [0011]      FIG. 3  depicts a partially exploded end cross sectional view of the table assembly of  FIG. 2 ; 
           [0012]      FIG. 4  depicts an end cross sectional view of the table assembly of  FIG. 2 ; 
           [0013]      FIG. 5  depicts the saw assembly of  FIG. 1  with the table assembly moved rearwardly along a cutting axis so as to allow a longer work piece to be positioned on the table assembly; 
           [0014]      FIG. 6  depicts the saw assembly of  FIG. 1  with the table assembly moved forwardly along a cutting axis so as to allow a longer work piece to be fully cut by the saw assembly; 
           [0015]      FIG. 7  depicts an end cross sectional view of an embodiment of a table assembly in accordance with principles of the present invention wherein wheels are contained within pockets defined by a base member; 
           [0016]      FIG. 8  depicts a perspective view of a carriage assembly of  FIG. 7 ; 
           [0017]      FIG. 9  depicts an end cross sectional view of an embodiment of a table assembly in accordance with principles of the present invention wherein wheels are contained within pockets defined by a work support member; 
           [0018]      FIG. 10  depicts a perspective view of a carriage assembly of  FIG. 9 ; and 
           [0019]      FIG. 11  depicts a perspective view of a rack and pinion arrangement of  FIG. 9 . 
       
    
    
     DESCRIPTION 
       [0020]    For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains. 
         [0021]      FIG. 1  depicts a saw system  100 . The saw system  100  includes a blade  102  which is rotatably driven by a power head assembly  104 . A support arm  106  supports the power head assembly  104  and blade  102  above a table assembly  108 . The table assembly  108 , also shown in  FIGS. 2 and 3 , includes a base member  110 , a work support member  112 , and two wheel carriage assemblies  114 / 116 . 
         [0022]    The wheel carriage assemblies  114 / 116  in one embodiment are substantially identical and include upper wheel members  120 / 122 , lower wheel members  124 / 126 , and a pair of intermediate wheel members  128 / 130 . Each of the wheel members  120 / 122 ,  124 / 126 , and  128 / 130  is rotatably supported by a respective carriage  132 / 134  through a pin  136 . Each of the wheel members  120 / 122 ,  124 / 126 , and  128 / 130  in this embodiment are identical and include a large diameter portion  140  and a small diameter portion  142  seen most clearly in  FIG. 3 . 
         [0023]    The base member  110 , which in some embodiments is fixedly positioned with respect to the support arm  106 , includes two guide slots  150  and  152  which extend inwardly from opposite sides  154 / 156  of the base member  110 . Each of the guide slots  150 / 152  includes a respective large diameter portion  158  and small diameter portion  160 . Stop plugs  162  (see  FIG. 2 ) are located at the end portions of each of the guide slots  150 / 152 . A pair of guide slots  164 / 166  extends inwardly from the upper surface  168  of the base member  110 . The guide slots  164 / 166  are parallel to one another. Each of the guide slots  164 / 166  is also parallel to, and directly above, one of the large diameter portions  158 . 
         [0024]    The work support member  112  includes two guide slots  170  and  172  which extend inwardly from opposite sides  174 / 176  of the work support member  112 . Each of the guide slots  170 / 172  includes a respective large diameter portion  178  and small diameter portion  180 . Stop plugs  182  (see  FIG. 2 ) are located at the end portions of each of the guide slots  170 / 172 . A pair of guide slots  184 / 186  extends inwardly from the lower surface  188  of the work support member  112 . The guide slots  184 / 186  are parallel to one another. Each of the guide slots  184 / 186  is also parallel to, and directly above, one of the large diameter portions  178 . The upper surface of the work support member  112  defines a generally planar work piece support surface. 
         [0025]    The large diameter portions  178  of the guide slots  150 / 152 / 170 / 172  are configured to receive the large diameter portions  140  of the wheels  120 / 122 / 124 / 126 . Accordingly, when the table assembly  108  is assembled as shown in  FIGS. 1 and 4 , the upper wheel  120  is received within the guide slot  170  of the work support member  112  with the large diameter portion  140  of the wheel  120  within the large diameter portion  158  of the guide slot  170  and the small diameter portion  142  of the wheel  120  within the small diameter portion  160  of the guide slot  170 . In like manner, the wheels  122 ,  124 , and  126  are received within the guide slots  172 ,  150 , and  152 , respectively. 
         [0026]    The engagement of the wheels  120 / 122 / 124 / 126  with the guide slots  170 / 172 / 150 / 152  keep the base member  110  and the work support member  112  assembled while allowing for movement of the carriages  114 / 116  with respect to both the base member  110  and the work support member  112 . Accordingly, the work support member  112  is also movable with respect to the base member  110 . 
         [0027]    Stability of the work support member  112  with respect to the base member  110  is provided by the intermediate wheel members  128  and  130 . Specifically, the lower surface  188  of the work support member  112  rests upon the small diameter portions  142  of the intermediate wheels  128 / 130  which in turn rest upon the upper surface  168  of the base member  110 . By increasing the distance between the intermediate wheels  128  and/or the intermediate wheels  130 , stability may be increased. In addition, the large diameter portion  140  of the intermediate wheel members  128  are received within the guide slots  164 / 184  while the large diameter portion  140  of the intermediate wheels  130  are received within the guide slots  166 / 186 . Accordingly, the intermediate wheels  128 / 130  assist in maintaining the table assembly  108  in an assembled condition and guide movement of the carriage assemblies  114 / 116 , and thus the work support member  112 , along the upper surface  168  of the base member  110 . 
         [0028]    The table assembly  108  allows for a relatively long work piece to be cut by the blade  102  while maintaining a relatively small footprint in the configuration of  FIG. 1 . For example, to accommodate a longer work piece, a user simply pulls the work support member  112  away from the blade  102  along a cutting axis  190  (see  FIG. 1 ). Such rearward movement of the work support member  112  results in rolling of the wheels  120 / 122 / 124 / 126 / 128 / 130 . Accordingly, the work support member  112  moves away from the blade  102 . More specifically, the lower surface  188  of the work support member  112  forces the wheels  128 / 130  to roll away from the blade  102 . As the wheels  128 / 130  roll, the work support member  112  moves rearwardly with respect to the wheels  128 / 130 . 
         [0029]    Rolling of the wheels  128 / 130  further results in rearward movement of the wheels  128 / 130  with respect to the base member  110 . Accordingly, the carriage assemblies  114 / 116  move rearwardly as the work support member  112  moves rearwardly. The resulting configuration is depicted in  FIG. 5 , where the carriage assemblies  114  and  116  ( 116  is not shown in  FIG. 5 ) are located at the rearward portion of the base member  110 , while the forward portion of the work support member  112  is supported by the carriage assemblies  114 / 116 . 
         [0030]    Consequently, a work piece that is much longer than the work support member  112  can be positioned on the work support member  112 . The work piece (not shown) may then be brought into contact with the blade  102  by moving the work support member  112  toward the blade  102 . Movement of the work support member in a forwardly direction reverses the above described movements so that the work support member  112  may be returned to the configuration of  FIG. 1 . 
         [0031]    Moreover, because the guide slots  150 / 152 / 164 / 166 // 170 / 172 / 184 / 186  extend along substantially the entire length of the base member  110  or support surface member  112  parallel to the cutting axis  190 , which is the axis along which the work support surface  112  moves, the work support surface  112 , and thus a work piece positioned thereon, can continue forwardly of the configuration of  FIG. 1  to the configuration of  FIG. 6 . In  FIG. 6 , the carriage assemblies  114  and  116  ( 116  is not shown in  FIG. 6 ) are located at the forward portion of the base member  110 , while the rearward portion of the work support member  112  is supported by the carriage assemblies  114 / 116 . 
         [0032]      FIG. 7  depicts a table assembly  200  that in some embodiments is used in place of the table assembly  108 . The table assembly  200  includes a base member  202  and a support surface member  204 . The support surface member  204  includes two flanges  206  and  208  which extend outwardly from rims  210  and  212 , respectively. Two carriage assemblies  214  and  216  are positioned on the flanges  206  and  208 , respectively. 
         [0033]    The carriage assemblies  214  and  216  are identical, and are described with reference to carriage assembly  214  which is also shown in  FIG. 8 . The carriage assembly  214  includes a carriage body  218  and three wheels  220 ,  222 , and  224 . Each of the wheels  218 ,  220 , and  222  are in contact with the flange  206 . The wheel  220  contacts an upper surface of the flange  206  while the wheels  222  and  224  contact a lower surface of the flange  206 . The wheels  220 / 222 / 224  are also in contact with the base member  202  as described below. 
         [0034]    The flanges  206 / 208  and the carriage assemblies  214 / 216  are located within pockets  230  and  232 , respectively, defined by the base member  202 . The pockets  230 / 232  are defined, in part, by lip portions  234  and  236 , respectively, which are coplanar with the upper surface of the support surface member  204 . 
         [0035]    The table assembly  200  works in a manner similar to the work table assembly  108 . One difference is that the carriage assemblies  214 / 216  include only three wheels ( 220 ,  222 , and  224 ). Only three wheels are used since the wheels  220 / 222 / 224  only provide for stability and movement between the base member  202  and the support surface member  204 . The wheels  220 / 222 / 224  do not directly maintain the table assembly  200  in an assembled condition. 
         [0036]    Rather, the components of the table assembly  200  are maintained in an assembled condition by the pockets  230 / 232  which enclose the carriage assemblies  214 / 216  and flanges  206 / 208 . Accordingly, when the table assembly  200  is incorporated into the system  100 , movement of the support surface member in a cross axial direction (i.e., a direction other than along the axis  190 ) is controlled. Movement of the carriage assemblies  214 / 216  out of the pockets  230 / 232  along the axis  190  of the table assembly  200  (i.e., a direction toward or away from the blade  102 ) may be controlled using stops similar to the stop plugs  182 . 
         [0037]    It will be appreciated that in the carriage assemblies  214 / 216 , the carriage body  218  ensured the wheels  222  and  224  remained spaced apart along the axis  190  so as to provide stability for the work support member  204 . In some embodiments, one or more of the carriage bodies is omitted. By way of example,  FIG. 9  depicts a table assembly  250  that in some embodiments is used in place of the table assembly  108 . The table assembly  250  includes a base member  252  and a support surface member  254 . The base member  252  includes two flanges  256  and  258  which extend inwardly. In this embodiment, pockets  260 / 262  are defined by upper flange portions  264 / 266  and lower flange portions  268 / 270  of the support surface member  254 . 
         [0038]    One carriage assembly  280  is positioned on the flange  256 . The carriage assembly  280  may include three or more wheels. In one embodiment, the carriage includes four wheels  282 ,  284 ,  286 , and  288  as depicted in  FIG. 10 . The wheels  282 ,  284 ,  286 , and  288  are rotatably supported by a carriage body  290  and in rolling contact with both the base member  252  and a support surface member  254 . Specifically, the wheels  282  and  284  contact the upper flange portion  264  and the flange  256  while the wheels  286  and  288  contact the lower flange portion  268  and the flange  256 . Because the wheels  282 ,  284 ,  286 , and  288  maintain a relatively fixed spacing between the base member  252  and a support surface member  254 , the wheels  282  and  284  need not be connected through the carriage body  290  to the wheels  286  and  288 . Accordingly, in one embodiment the carriage body  290  is split into two sub carriage bodies, each sub carriage body supporting two wheels. 
         [0039]    Rather than a carriage assembly within the pocket  262 , two rack and pinion assemblies  292  and  294  are provided. The rack and pinion assemblies  292  and  294  are substantially identical and are described with reference to rack and pinion assembly  292  as depicted in  FIG. 11 . The rack and pinion assembly  292  includes two racks  296  and  298 . The rack  296  is mounted to the upper flange portion  266  while the rack  298  is mounted to the flange  258 . The racks  296 / 298  may be flush mounted to or formed (molded) or machined into the support structure. 
         [0040]    The rack and pinion assembly  292  further includes two pinions or gears in the form of wheels  300  and  302 . The wheels  300  and  302  are meshingly engaged with both the rack  296  and the rack  298 . Because the wheels  300  and  302  are toothed, spacing between the wheels  300  and  302  is automatically maintained. Accordingly, there is no need for a carriage body to maintain distance between the wheels  300  and  302  alongthe axis  190 . Moreover, because of the pocket and flange configuration, a carriage body is not required in order to maintain the desired vertical (with respect to the view of  FIG. 9 ) relationship between the base member  252  and a support surface member  254 . Accordingly, some embodiments incorporate a rack and pinion arrangement in place of a carriage assembly in both pockets. 
         [0041]    While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the invention are desired to be protected.