Abstract:
A portable table saw in one embodiment includes a base, a first support post and a second support post, each of the first and second support post extending upwardly to a location higher than the base, at least one support rail having a first end portion supported by the first support post and a second end portion supported by the second support post, a saw movably mounted to the at least one support rail at a location between the first end portion and the second end portion, the saw positioned above the base and movable along the at least one support rail, and a first pivot mechanism configured to pivot the saw with respect to the base.

Description:
FIELD OF THE INVENTION 
       [0001]    This patent relates generally to the field of devices used to support and shape work-pieces and particularly to a device for supporting and cutting work-pieces. 
       BACKGROUND 
       [0002]    Laminate flooring is a popular flooring product due to its ease of installment as well as its performance. Additionally, the various designs which are available for laminate flooring enhance its popularity with consumers. The designs include wood-grain patterns, slate, marble, mosaic, and granite. Additionally, a number of specialized products have been designed to ease installation of laminate flooring. Such products include transition strips, end caps, stair nosings, moldings and baseboards. 
         [0003]    When laminates were first introduced, there was only one method of installation. The laminates were produced in a “tongue and groove” design. When installing the laminate, the tongue and grooves were glued together, then clamped and left to dry. Manufacturers have since developed flooring that requires no glue at all. 
         [0004]    Accordingly, installation of laminate flooring has been significantly simplified. One difficult aspect of installation that remains, however, is cutting the laminate flooring to fit within a particular area. Most laminates are provided in planks that are 7-8 inches wide and about 4 foot long. Depending upon the width of a room, the final course of planks may need to be ripped to the appropriate width. Moreover, the lengths of the planks at opposing walls need to be trimmed. Additionally, miter cuts may be required to contour the planks to fit the contours of a particular room. 
         [0005]    Once the flooring has been installed, a baseboard or trim is typically installed on the walls adjacent to the flooring. At locations where walls meet, the trim is generally mitered so as to form a finished corner. Miter cuts of this type require a different orientation of the work piece compared to miter cuts on flooring work pieces. A typical flooring saw, however, does not provide the requisite clearing to accommodate trim pieces of more than about an inch. 
         [0006]    Traditionally, a number of different types of saws have been used to make the necessary miter and rip cuts in laminate floors and baseboards. Such saws include table saws, hand saws, jig saws and circular saws. Each of these types of saws provides some advantages. A table saw gives very precise cuts and can be used to rip cut a work-piece. Additionally, table saws can be configured to provide angled cuts by angling the work-piece and/or the saw blade. Table saws can also accommodate baseboards and trim pieces which can have heights of up to seven inches. Table saws, however, even the so called “portable” table saws, are large and heavy. Thus, an installer must either undertake the difficulty of transporting the table saw to a location near the area where the laminate and trim is to be installed or carry each piece of laminate and trim back and forth from the work area to the saw location. Additionally, many homeowners attempt to install a laminate floor on their own. In the event the homeowner does not own a table saw, a different approach is needed. 
         [0007]    Hand saws are, in stark contrast to table saws, extremely mobile. Hand saws are also, however, labor intensive. Thus, while handsaws may reasonably be used to make cuts of a few feet, the large number of planks that may need to be cut for a particular installation presents a daunting challenge to those using handsaws. Moreover, handsaws are generally not as accurate as table saws which can result in unacceptable joints in trim work. 
         [0008]    Jig saws and circular saws are generally much more “portable” than table saws and greatly facilitate making a large number of cuts. Depending upon the particular jigs available to an installer, however, these saws still do not provide the accuracy achievable with a table saw. Thus, while professional installers may become very skilled with using a jig saw or circular saw, other users may generate an undesired amount of scrap as a result of erroneous cuts. 
         [0009]    What is needed is a system which can be used to rip cut a work piece and to miter cut the work piece. What is further needed is a system which is portable so that it can be located at a work site. A further need is for a system that can provide the required portability while providing accurate cuts. Yet another need is for a system that can accommodate work pieces of increased height. 
       SUMMARY 
       [0010]    In accordance with one embodiment of the disclosure, a portable table saw includes a base, a first support post and a second support post, each of the first and second support post extending upwardly to a location higher than the base, at least one support rail having a first end portion supported by the first support post and a second end portion supported by the second support post, a saw movably mounted to the at least one support rail at a location between the first end portion and the second end portion, the saw positioned above the base and movable along the at least one support rail, and a first pivot mechanism configured to pivot the saw with respect to the base. 
         [0011]    In another embodiment, a saw system includes a base, a first support post and a second support post, each of the first and second support post extending upwardly to a location higher than the base, at least one support rail supported by the first support post at a first location and supported by the second support post at a second location, a saw movably mounted to the at least one support rail at a location between the first location and the second location, the saw positioned above the base and movable along the at least one support rail, and at least one pivot mechanism configured to pivot the saw with respect to the base. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  depicts a perspective view of a power tool system in accordance with principles of the present invention; 
           [0013]      FIG. 2  depicts a front plan view of the system of  FIG. 1 ; 
           [0014]      FIG. 3  depicts a perspective view of the base portion of the pivot mechanism of the system of  FIG. 1 ; 
           [0015]      FIG. 4  depicts a perspective view of the guide follower portion of the pivot mechanism of the saw system of  FIG. 1 ; 
           [0016]      FIG. 5  depicts a perspective view of the guide follower portion of  FIG. 4  inserted within the base portion of  FIG. 3 ; 
           [0017]      FIG. 6  depicts a front plan view of the flooring saw system of  FIG. 1  with the power tool pivoted with respect to the base portion of the system; 
           [0018]      FIG. 7  depicts a perspective view of a power tool system in accordance with principles of the invention, wherein the power tool is removed and the support rails are pivoted using two pivot mechanisms located at opposite ends of the support rails; and 
           [0019]      FIG. 8  depicts a laid open perspective view of a pivot mechanism of  FIG. 7 . 
       
    
    
     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]      FIGS. 1 and 2  show a power tool system  100 . The system  100  includes a base  102 , a support structure  104  and a fence  106 . A power tool  108  is supported by the support structure  104 . The base  102  includes a work piece support surface  110  which defines a support plane. A blade slot  112  extends completely through the work piece support surface  110  to a lower surface  114 . 
         [0022]    The fence  106  is removably supported on the work piece support surface  110 . The fence  106  and the work piece support surface  110  may be configured to allow the fence  106  to be positioned in a number of orientations. By way of example, the fence  106  and the work piece support surface  110  may be configured like the fence and work piece support surface disclosed in U.S. Patent Application Publication No. 2010/0116111, published on May 13, 2010. 
         [0023]    The support structure  104  in the embodiment of  FIGS. 1 and 2  includes two support posts  120  and  122 , two support rails  124  and  126 , and a pivot mechanism  128 . The support posts  120  and  122  are fixedly mounted to the base  102  and extend upwardly to a location above the support plane defined by the work piece support surface  110 . The support post  120  supports the support rails  124  and  126  at one end of the support rails  124  and  126  while the opposite end of the support rails  124  and  126  is supported by the support post  122 . The longitudinal axes of the support rails  124 / 126  are parallel to the longitudinal axis of the blade slot  112 . 
         [0024]    The pivot mechanism  128 , shown in additional detail in  FIGS. 3 and 4 , includes a pivot base member  130  and a pivoting member  132 . The base member  130  includes a support bracket  134 , a clamp lever  136 , and a guide portion  138 . The support bracket  134  includes two bores  140  and  142  which slidingly receive the support rails  124  and  126 , respectively (see  FIG. 1 ). The clamp lever  136  is operatively connected to two clamp members  144  and  146  located within the bores  140  and  142 . The clamp lever  136  is used to move the clamp members  144  and  146  between a first position whereat the clamp members  144  and  146  clamp the support rails  124  and  126 , thereby positionally locking the bracket  134 , and a second position whereat the clamp members  144  and  146  do not clamp the support rails  124  and  126 , thereby allowing the bracket  134  to move along the support rails  124  and  126  between the support posts  120  and  122 . 
         [0025]    The guide portion  138  includes a guide slot  150 . The guide slot  150  has an inner guide surface  152  and an outer guide surface  154 . The inner guide surface  152  has a radius R 1  which has an origin  156 . The outer guide surface  154  has a radius R 2  which shares the origin  156  with R 1 . 
         [0026]    The pivoting member  132  is fixedly attached to the power tool  108  and includes a guide follower portion  160  which includes two articulating guide surfaces  162  and  164  which are positioned within the guide slot  150  when the pivot mechanism  138  is assembled as shown in  FIG. 5 . The articulating guide surface  162  has a radius R 3  which has an origin  166 . The articulating guide surface  164  has a radius R 4  which shares the origin  166  with R 3 . 
         [0027]    When the guide follower portion  160  is positioned within the guide slot  150  as shown in  FIG. 5 , the origin  156  is collocated with the origin  166 . Additionally, R 1  is substantially identical to R 3  and R 2  is substantially equal to R 4 . Accordingly, the guide follower portion  160  is tightly received within the guide slot  150 . The inner and outer guide surfaces  152 / 154  and the articulating guide surfaces  162 / 164 , however, are configured for articulating contact. Accordingly, the guide follower portion  160  may be moved within the guide slot  150 . 
         [0028]    When movement within the guide slot  150  is not desired, a locking member  168  (see  FIG. 2 ) which is received within a locking bore  170  (see  FIG. 4 ) in the guide follower portion  160  may be used to fix the location of the guide follower portion  160  within the guide slot  150 . In one embodiment, the guide portion  138  is clamped between the locking member  168  and the power tool  108 . 
         [0029]    The power tool  108  in the embodiment of  FIG. 1  is a power saw. Referring again to  FIGS. 1 and 2 , the power tool  108  includes a blade guard  180  which is configured to receive a blade  182 . The power tool  108  thus defines a working portion plane in the form of a saw blade plane in which the blade  182  is positioned when mounted to the power tool  108 . The power tool  108  further includes two kick-back pawls  184  and  186  which extend from the blade guard  180  and a riving knife  188  located at the rear of the blade guard  180 . 
         [0030]    The portable saw system  100  may be operated in accordance with the following example or variants thereof. Initially, the portable table saw system is configured substantially as depicted in  FIG. 1 . In  FIG. 1 , the fence  106  is positioned on the work piece support surface  110 . The blade  182 , when positioned within the saw blade plane, extends from the power tool  108  to within the blade slot  112 . Additionally, the guide follower portion  160  of the pivot mechanism  128  is positioned within the slot and locked with the locking member  168  shown in  FIG. 2 . 
         [0031]    The user can adjust the angle of the cut to be made on a work piece by first loosening the locking member  168  ( FIG. 2 ). The power tool  108  is then pivoted about the base  102 . Specifically, by applying an upward force (as viewed in  FIG. 2 ) on the power tool  108 , the guide follower portion  160  of the pivot mechanism  128  is forced along the guide slot  150 . Because R 1  is substantially equal to R 3 , and because R 2  is substantially equal to R 4 , the power tool  108  pivots about a pivot axis on which the origins  156 / 166  (see  FIGS. 3 and 4 ) are located. 
         [0032]    The portable saw system  100  is configured such that the origins  156 / 166  are located at or about the intersection of the working portion plane defined by the power tool  108  and the support plane defined by the work piece support surface  110  at a location directly above the blade slot  112 . Accordingly, as the power tool  108  pivots from the position of  FIG. 2  to the position of  FIG. 6 , the saw blade  182  intersects the support plane at substantially the same location throughout the pivoting movement. Once the power tool  108  has been pivoted to the position of  FIG. 6 , the locking member  168  may be used to positionally fix the guide follower portion  160  within the guide slot  150 . 
         [0033]    Locking of the guide follower portion  160  within the guide slot  150  firmly locks the angle of the power tool  108  with respect to the base  102 . The stability of the lock is enhanced because of the tight fit of the articulating guide surfaces  162 / 164  against the inner and outer guide surfaces  152 / 154 . 
         [0034]    A work piece may then be positioned on the work piece support surface  110  and against the fence  106 . The clamp lever  136  may then be used to loosen clamp members  144 / 146  thereby allowing the power tool  108  to be moved along the support rails  124 / 126 . Upon energizing the power tool  108 , the user can force the power tool  108  along the support rails  124 / 126  until the blade  182  cuts into the work piece to the desired extent. 
         [0035]    The portable saw system  100  thus provides a power tool  108  that is movably mounted to the support rails  124 / 126  and which may be moved along the support trails  124 / 126  or locked in a desired position using the clamp lever  136 . Because the power tool  108  is pivotably mounted to the support rails  124 / 126  by the pivot mechanism  128 , the power tool  108  may be locked at a variety of angles with respect to the base  102  to allow angled cuts on a work piece. 
         [0036]    If desired, the location of a pivot mechanism may be modified while maintaining various advantages of the power saw system  100 . By way of example,  FIG. 7  depicts an alternative power saw system  200 . The power tool system  200  includes a base  202  and a support structure  204 . A fence (not shown) such as the fence  106  may be used with the power tool system  200  and a power tool (not shown) may supported by the support structure  204 . The base  202  includes a work piece support surface  210  which defines a support plane. A blade slot  212  extends completely through the work piece support surface to a lower surface  214 . 
         [0037]    The support structure  204  in the embodiment of  FIG. 6  includes two support posts  220  and  222 , two support rails  224  and  226 , and two pivot mechanisms  228  and  230 . The support posts  220  and  222  are fixedly mounted to the base  202  and extend upwardly to a location above the support plane defined by the work piece support surface  210 . 
         [0038]    The pivot mechanisms  228  and  230  are substantially mirror images of each other, and are described with reference to the pivot mechanism  228 . The pivot mechanism  228  includes a guide member  238  (see  FIG. 7 ) which is fixedly attached to the support post  220 . The guide member  238  has an inner guide surface  240  and an outer guide surface  242 . The pivot mechanism  228  further includes a pivoting member  244  that includes a guide follower portion  246  with a slot  248  which includes two articulating guide surfaces  250  and  252 . The pivot mechanism further includes a bracket  254  which supports an end portion of the support rails  224 / 226 . 
         [0039]    The radii of curvature of the inner and outer guide surfaces  240 / 242  and the articulating guide surfaces  250 / 252  are configured in the same manner as the inner and outer guide surfaces  150 / 152  and the articulating guide surfaces  162 / 164 . Accordingly, the origins of the radii of curvature of the inner and outer guide surfaces  240 / 242  and the articulating guide surfaces  250 / 252  are collocated when the pivot mechanism  228  is assembled. 
         [0040]    Additionally, the blade slot  212  is parallel to and spaced apart from the support rails  224 / 226  such that the origin of the radii of curvature of the inner and outer guide surfaces  240 / 242  and the articulating guide surfaces  250 / 252  is at or about directly above the blade slot  212  in the support plane defined by the work piece support surface  210 . Accordingly, the pivot mechanisms  228  and  230  may be used to pivot the support rails  224 / 226  about a pivot axis that is located at or about directly above the center of the blade slot  212  in the support plane. 
         [0041]    In a further embodiment, in addition to the power tool and the support rails, the support posts may also be pivoted. In such an embodiment, which may be otherwise substantially the same as the embodiments described above, the location of the pivot mechanisms is modified such that one portion of the pivot mechanism is fixed to the base of a power tool system and another portion of the pivot mechanism that is fixed to the support posts. 
         [0042]    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.