Abstract:
A workpiece stop is provided for a power tool such as a miter saw, wherein the stop is selectively movable to various positions for respective modes of operation. In one position, the stop is stored out of the way during non-use. In another position, the stop acts as a length-of-cut stop. In yet another position, the stop acts as a workpiece guide, especially useful for supporting crown molding during cutting. An embodiment of the stop includes an elongate main body portion with a guide tab portion and a stop tab portion projecting from the main body portion, and the stop is preferably mounted for selective movement both slidably and pivotally. Depending on the position of the stop, the guide tab portion or the stop tab portion are positioned to project adjacent a workpiece support surface on the saw to limit a position of a workpiece.

Description:
FIELD OF THE INVENTION 
   The invention generally relates to power saws and more particularly relates to saws having workpiece stop and guide mechanisms. 
   BACKGROUND OF THE INVENTION 
   Miter saws are generally known for cutting wood. Conventional miter saws provide a horizontal workpiece support surface and a vertical fence for supporting a workpiece during sawing. 
   It is also known to mount a stop member to limit the position of a workpiece placed on the support surfaces. One known type of stop member sets a predetermined distance from the blade to permit cutting of a workpiece to a predetermined length. The stop member is typically mounted on an extendable structure so that the cut length can be adjusted as desired. 
   Another known type of stop acts as a guide for supporting a crown molding workpiece. Miter saws are commonly used for cutting corners on crown molding, a task that may require a compound cut angle. Due to the cross sectional shape of crown molding, it has been necessary to provide a guide disposed a distance forwardly of the fence to support a front edge of the crown molding in order to hold the crown molding at an appropriate position. The guide is positioned at a predetermined distance forwardly of the fence to support crown molding at an appropriate angle as it rests against the fence for cutting. 
   It is desirable to provide a miter saw that includes a stop useful to set a predetermined workpiece cut length and that also includes a guide tab useful to appropriately hold crown molding. Additionally, a need exists for an improved stop for a miter saw that provides easy selection and adjustment of a stop tab and a guide tab. 
   BRIEF SUMMARY OF THE INVENTION 
   In an embodiment, the invention provides an improved miter saw having a multi-mode workpiece stop. Preferably, the stop is operable in one mode as a length-of-cut stop and in another mode as a crown molding guide, wherein the stop can be switched between these modes with a “flip-up” motion. 
   For example, according to an embodiment, a miter saw is provided comprising a stationary base having a generally horizontal workpiece support surface and a fence mounted to the base. The fence has a planar, vertically-oriented workpiece support surface that extends in a direction along a horizontal workpiece axis, and the horizontal workpiece support surface extends horizontally from the fence in a forward direction. The miter saw also includes a saw unit that is mounted to the base for relative movement, and the saw unit has a circular saw blade for cutting a workpiece. Furthermore, the miter saw includes a stop comprising a main body portion, a guide tab portion extending from the main body portion, and a stop tab portion extending from the main body portion. The main body portion is mounted for selective movement relative to the base among multiple positions including: (a) a first position, or “storage position,” in which both the stop tab portion and guide tab portion are free from the workpiece support surfaces so as to permit free positioning of a workpiece on the workpiece support areas; (b) a second position, or “workpiece stop position,” operable as an end stop wherein the stop tab portion projects perpendicularly to at least one of the workpiece support surfaces to limit a position of an end of a workpiece along the workpiece axis; and (c) a third position, or “workpiece guide position,” operable as a crown molding guide wherein the guide tab portion projects upwardly from the horizontal workpiece support surface, the guide tab portion opposing the fence, spaced a distance forwardly of the fence, effective to support an edge of a workpiece at a predetermined distance forwardly of the fence. 
   In an embodiment, the main body portion is mounted to the base for selectively slidable relative movement. In a related embodiment, the stop is movable from the first position to the second position by sliding the stop forwardly. 
   In an embodiment, a fastener is provided to selectively secure the stop in a desired position relative to the base. For example, in an embodiment wherein an elongate slot is disposed through the main body portion, the fastener may be a threaded mounting bolt that extends through the slot and that is received within a threaded bore in the base, wherein the fastener is selectively tightenable to secure the stop relative to the base. 
   In an embodiment, the main body portion is cooperatively shaped to fit against the base to hold the stop in a manner such that the slot is generally horizontal. In a related embodiment, the main body portion includes an elongate channel and the base includes at least one ridge shaped to cooperatively fit within the channel. The slot is disposed parallel to and within the channel, and the stop can slidably adjust along the ridge. Alternatively, a channel is disposed in the base and the stop cooperatively fits with the channel. 
   In an embodiment, when the stop is in the third position, the stop is selectively slidable to position the guide tab at a desired distance forwardly of the fence. 
   In an embodiment, the stop is mounted to the base for selectively pivotable movement. 
   In an embodiment, the stop is movable between the first position and the third position by pivoting the stop forwardly 180 degrees. 
   In an embodiment, the stop is movable between the second position and the third position by pivoting the stop forwardly 180 degrees. 
   An advantage of the present invention is that it provides an improved stop for a miter saw. 
   Another advantage of the present invention is that it provides a stop that is operable in multiple modes. In an embodiment, a further advantage of the present invention is that it provides a stop for a miter saw, wherein the stop moves out of the way of workpiece support surfaces, when desired, in order to not limit the position of a workpiece. 
   In an embodiment, an advantage is that the stop is mounted for slidable and pivotable movement to permit quick selection between modes of operation and ease of adjustability. 
   These and other advantages of the invention will be apparent from the description of the invention provided herein. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a miter saw including a stop constructed in accordance with teachings of the present invention. 
       FIG. 2  is an exploded, fragmentary, perspective view of the miter saw of  FIG. 1 , illustrating the stop. 
       FIG. 3  is a fragmentary side elevation of the miter saw illustrating the stop in a first position for out-of-the-way storage during non-use, wherein the stop tab portion and guide tab portion are free from the workpiece support surfaces to not limit the position of a workpiece. 
       FIG. 4  is a fragmentary side elevation of the miter saw illustrating the stop in a second position, slid forwardly of the first position, wherein the stop tab portion projects from the workpiece support surface, operable to stop a workpiece thereby set a desired cut length. 
       FIG. 5  is a fragmentary side elevation of the miter saw illustrating the stop slid rearwardly in preparation for adjustment between the first and third positions. 
       FIG. 6  is a fragmentary side elevation of the miter saw illustrating the stop being “flipped” or pivoted forwardly toward the third position. 
       FIG. 7  is a fragmentary side elevation of the miter saw illustrating the stop being “flipped” or pivoted forwardly toward the third position. 
       FIG. 8  is a fragmentary side elevation of the miter saw illustrating the stop in the third position wherein the guide tab is positioned parallel to the fence, spaced a distance forwardly of the fence. 
       FIG. 9  is a fragmentary side elevation of the miter saw illustrating the stop in the third position, the guide tab being adjusted at a desired distance from the fence appropriate to hold a front edge of a small piece of crown molding during a cutting operation. 
       FIG. 10  is a fragmentary side elevation of the miter saw illustrating the stop in the third position, the guide tab being adjusted at a desired distance from the fence appropriate to hold a front edge of a large piece of crown molding during a cutting operation. In  FIG. 10 , the stop is adjusted so that the guide tab is positioned a greater distance from the fence than in  FIG. 9 . 
       FIG. 11  is a fragmentary front elevation of the miter saw illustrating the stop in the third position. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Now referring to the drawings, wherein like numerals designate like components,  FIG. 1  illustrates a miter saw  20 . The miter saw  20  includes a base  22  having a generally planar, horizontal workpiece support surface  24 . A fence  26  is mounted to the base  22 , the fence  26  having a generally planar, vertical workpiece support surface  28 . A workpiece support axis W ( FIG. 2 ) generally extends horizontally parallel to the fence  26 . 
   The miter saw  20  further includes a table  30  that is rotatably mounted to the base  22 , and an arm  32  is mounted to a rear of the table  30 . The arm  32  holds a saw unit  34  with a circular blade  36 . The table  30  is rotatably adjustable relative to the fence  26 , so that the table (and saw unit mounted thereon) can be angularly positioned to set a desired miter cut angle. The arm  32  is pivotably mounted to permit the saw unit  34  to be moved toward downward to cut a workpiece on the support surface  24 . Preferably, the arm  32  is mounted to permit a lateral angular adjustment to tilt the blade  36  to a desired compound cut angle. 
   According to an aspect of the invention, the miter saw includes a workpiece stop that is operable in multiple modes. In one mode, the stop is operable as a length-of-cut stop, and in another mode the stop is operable as a crown molding guide, and the stop can be switched between these modes with a “flip” motion. In a further mode, the stop is positioned out of the way when not in use. 
   For example, as illustrated in  FIGS. 1–11 , the miter saw has a stop  40 . The stop  40  is pivotally mounted to the base  22  near an end of the fence  26 . In the illustrated embodiment, as can be viewed in  FIGS. 2–11 , the stop  40  includes a main body portion  42 , a guide tab portion  44  that extends from the main body portion, and a stop tab portion  46  that extends from the main body portion. The stop  40  is mounted to the base in a manner that permits it to be selectively positioned. 
   A fastener  50  is provided to selectively secure the stop  40  relative to the base in a desired position. For example, in the illustrated embodiment, the fastener  50  is a threaded mounting bolt. In such embodiment, an elongate slot  48  is disposed through the main body portion  42  to facilitate selective positioning of the stop  40  relative to the base  22  with either a sliding or pivotal motion. Also in the embodiment wherein the fastener  50  is a bolt, the fastener extends through the slot  48  and is received within a threaded bore  52 R in the base  22 . The fastener  50  is selectively tightenable to press the main body portion  42  against the base  22 , thereby securing the stop  40  in a fixed position relative to the base. When the fastener  50  is loosened so as to relieve friction between the main body portion  42  and the base  22 , the stop  40  is slidably movable on the fastener  50 , which glides within the slot  48 . It will be appreciated that the fastener  50  could be any one of a variety of structures, and it is not limited to the bolt illustrated. For example, the fastener  50  could alternatively be a cam device, a clip, or any device operable to secure the stop  40  relative to the base  22 , preferably in a quick-change manner. 
   In order to maintain proper alignment of the stop  40  during a slidable adjustment, the main body portion  42  is preferably shaped to cooperatively fit against the base to hold the stop in a manner such that the slot is generally horizontal. In the illustrated example, the main body portion  42  has a generally elongate, channel-like shape. Turning to  FIG. 11 , the main body portion  42  is shaped to form elongate rails  47  and  49 , defining the channel. Additionally, the base  22  includes at least one ridge  54  shaped to cooperatively fit within a concave portion of the channel, as illustrated in  FIG. 11 , in a manner that guides the stop  40  for horizontal slidable movement.  FIG. 11  illustrates that the ridge  54  fits within the channel in contact with the upper and lower rails  47 ,  49 , to provide support that maintains the desired orientation. Alternatively, a channel is disposed in the base and the stop cooperatively fits with the channel. 
     FIG. 11  also illustrates that the stop  40  is preferably dimensioned to form a gap G between the ridge  54  and the main body portion  42 . The gap G ensures that the mounting contact is transferred through the rails  47 ,  49 . Thus, when the fastener  50  is tightened against an outer surface of the main body portion  42 , the rails  47 ,  49  contact firmly against the base  22  respectively above and below the ridge  54 , securing the stop  40  in the desired position. 
   When the stop  40  is in a storage mode and not being used, the stop is secured in a first position as illustrated in  FIG. 3 . In the first position, both the stop tab portion  46  and guide tab portion  44  are free from the workpiece support surfaces  24 ,  28  so as to permit free positioning of a workpiece on the workpiece support surfaces. The stop tab portion  46  is directed upwardly and is positioned at least flush with (shown), or rearwardly of, the vertical workpiece support surface  28  of the fence  26 . The guide tab portion  44  is downwardly directed downwardly from a rearmost end of the stop  40 , well out of the way of the workpiece support surfaces  24 ,  28 . 
   In order to use the stop  40  in an end stop mode, the stop is placed in a second position, as illustrated in  FIG. 4 . In the second position, the stop tab portion  46  is positioned forwardly of the vertical workpiece support surface  28  of the fence  26  and projects perpendicularly upwardly above the horizontal workpiece support surface  24  of the base  22 . In this position, the stop tab portion  46  will abut a workpiece that is positioned on the workpiece support surface  24 . As a result, the stop tab portion  46  sets a predetermined distance from the blade  36  to permit cutting of a workpiece to a predetermined length between the blade and the stop tab portion  46 . The stop  40  is easily movable between the first position ( FIG. 3 ) and the second position ( FIG. 4 ) with a horizontal sliding action while the stop  40  maintains a consistent orientation. The guide tab portion  44  remains out of the way of the workpiece support surfaces and is not used in the position of  FIG. 4 . 
   In a preferred embodiment, the base  22  and fence  26  are constructed in an outwardly extendable manner (see  FIG. 2 ), so that the workpiece support surfaces  24 ,  28  can be extended in a direction of the workpiece axis W. The stop  40  is mounted on an end of the base  22 , and therefore, the stop tab portion  46  is outwardly extended at the same time to permit adjustment of the cut length. 
   In a mode wherein the stop  40  serves as a crown molding guide, the stop is placed in a third position as illustrated in  FIG. 8 . Preferably, the stop  40  is movable to the third position with a “flip-up” action wherein the stop is pivoted about 180 degrees from its orientation in the first position ( FIG. 3 ) or the second position ( FIG. 4 ). The “flip-up” motion will be described with reference to  FIGS. 5–8 . From the first or second position, when the fastener  50  is loosened, a user can slide the stop  50  rearwardly as shown in  FIG. 5 . When the stop is pulled rearwardly, an end of the slot  48  hits the fastener  50 , and the ridge  54  is free of the channel, permitting the stop to be pivoted.  FIGS. 6 and 7  illustrate a forward pivot action of the stop  40 , until the stop  40  finally reaches the horizontal orientation shown in  FIG. 8 , which is 180 degrees from the orientation of the stop in  FIGS. 3 and 4  so that the guide tab portion  44  is at a forward end of the stop  40  and projects upwardly from the main body portion  42 . Also, the guide tab portion  44  projects upwardly from the horizontal workpiece support surface  24 , opposing the fence  26 . 
     FIGS. 9 and 10  show the stop  40  in the third position and in use as a crown molding guide. In  FIGS. 9 and 10 , the guide tab portion  44  is spaced a desired distance forwardly of the fence, effective to support a front edge of a crown molding workpiece  60 A at a predetermined distance forwardly of the vertical workpiece support surface  28  of the fence  26 . By setting the stop  40  so that the slot  48  is a desired position on the fastener  50 , the stop can be slidably adjusted within the third position to accommodate different workpiece sizes. For example,  FIG. 9  shows the stop  40  positioned so that the guide tab portion guides a front edge of a small piece of crown molding. Moreover, the base preferably includes an auxiliary threaded bore  52 F positioned forwardly of the threaded bore  52 R. The fastener  50  may be tightened into the bore  52 F ( FIG. 2 ), instead of  52 R ( FIG. 2 ), in order to set the position of the guide tab portion  44  to accommodate a large sized workpiece  60 B, as illustrated in  FIG. 10 . As shown in  FIGS. 9 and 10 , the stop tab portion  46  is directed downwardly, out of the way of the workpiece  60 A,  60 B, and is not used. 
   All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein. 
   The use of the terms “a” and “an” and “the” and similar referents in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention. 
   Preferred embodiments of this invention are described herein, including the best mode known to the inventors for carrying out the invention. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the invention.