Abstract:
An assembly comprises a support table including a support table orifice; a insert plate within the support table orifice; and at least one mounting and leveling apparatus. The mounting and leveling apparatus comprises a clamp screw; at least two leveling screws; at least one mounting screw; and a mounting bracket that defines a first threaded hole that threadably engages the clamp screw, a second hole that receives the at least one mounting screw and a third set of threaded holes that each threadably engages one of the at least two leveling screws. The clamp screw pulls the insert plate towards the mounting bracket when tightened. The at least one mounting screw couples the mounting bracket to the support table. The at least two leveling screws are independently adjustable to allow a top surface of the insert plate to be precisely aligned with a top surface of the support table.

Description:
TECHNICAL FIELD 
     The invention relates to insert plates for a workpiece support table, such as support table for a router. 
     BACKGROUND 
     Powered hand tools, such as, for example, routers, handsaws, drills, planers, and the like, are often mounted to a planar support structure, such as a support table, to allow simplified operation, for example, when operating on large workpieces. Precise operations, such as routing, cutting and/or sanding operations using a support table require that the powered hand tool is precisely positioned relative to the support table. Frequently, a powered hand tool is first fixed to an insert plate that is then mounted flush to the support table. To facilitate this mounting, a support table may include an approximately central through-hole to receive the powered hand tool mounted to the insert plate. 
     SUMMARY 
     In general, the invention relates to leveling an insert plate for a support table. Leveling is accomplished using a set of mounting and leveling apparatuses to attach the insert plate to the support table. The mounting and leveling apparatuses include at least one leveling device, such as a screw or bolt, which may be adjusted to change the distance between the insert plate and mounting bracket in order to mount the insert plate flush with the top surface of the support table. As the distance between the insert plate and mounting bracket is changed, the relative position of a surface of the insert plate changes with respect to the top surface of the support table. 
     In an embodiment, an assembly comprises a support table including a support table orifice; a insert plate within the support table orifice; and at least one mounting and leveling apparatus. The mounting and leveling apparatus comprises a clamp screw; at least two leveling screws; at least one mounting screw; and a mounting bracket that defines a first threaded hole that threadably engages the clamp screw, a second hole that receives the at least one mounting screw and a third set of threaded holes that each threadably engages one of the at least two leveling screws. The clamp screw pulls the insert plate towards mounting bracket when tightened. The at least one mounting screw couples the mounting bracket to the support table. The at least two leveling screws are independently adjustable to allow a top surface of the insert plate to be precisely aligned with a top surface of the support table. 
     Another embodiment is directed to a mounting and leveling apparatus, for mounting an insert plate to a support table. The mounting and leveling apparatus comprises a clamp screw; at least two leveling screws; at least one mounting screw; and a mounting bracket that defines a first threaded hole that threadably engages the clamp screw, a second hole that receives the at least one mounting screw and a third set of threaded holes that each threadably engages one of the at least two leveling screws. The clamp screw pulls the insert plate towards mounting bracket when tightened. The at least one mounting screw couples the mounting bracket to the support table. The at least two leveling screws are independently adjustable to allow a top surface of the insert plate to be precisely aligned with a top surface of the support table. 
     In another embodiment, a kit for mounting an insert plate to a support table comprises at least two mounting and leveling apparatuses and instructions for mounting the insert plate to the support table using the at least two mounting and leveling apparatuses. Each of the mounting and leveling apparatuses comprise a clamp screw; at least two leveling screws; at least one mounting screw; and a mounting bracket that defines a first threaded hole that threadably engages the clamp screw, a second hole that receives the at least one mounting screw and a third set of threaded holes that each threadably engages one of the at least two leveling screws. The clamp screw pulls the insert plate towards mounting bracket when tightened. The at least one mounting screw couples the mounting bracket to the support table, and the at least two leveling screws are independently adjustable to allow a top surface of the insert plate to be precisely aligned with a top surface of the support table. 
     The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG. 1  illustrates a mounting and leveling apparatus for coupling a insert plate to a support table. 
         FIG. 2  illustrates a mounting and leveling apparatus coupled to a insert plate. 
         FIG. 3  illustrates a view of support table, four mounting and leveling apparatuses and a insert plate. 
         FIG. 4  illustrates a mounting bracket registered to a support table orifice. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 1-3  generally illustrate a mounting and leveling apparatus  100  for coupling a insert plate  200  to support table  300 . As best seen in  FIG. 1 , the mounting and leveling apparatus  100  includes mounting bracket  102 , clamp screw  104 , first leveling screw  106   a  and second leveling screw  106   b  (collectively “leveling screws  106 ”). Apparatus  100  further includes first mounting screw  108   a , second mounting screw  108   b  and third mounting screw  108   c  (collectively “mounting screws  108 ”). 
     As best seen in  FIG. 2 , insert plate  200  includes top surface  202  and bottom surface  204  substantially opposite top surface  202 . Top and bottom surfaces  202 ,  204  are joined by periphery wall  206 , which in the illustrated embodiment defines a generally rectangular shape of insert plate  200 . In other embodiments, insert plate  200  may be generally triangular, circular or elliptical, or may include any other desired geometry. 
     A hand tool (not shown) is generally fixed to insert plate  200  by screws or other suitable mechanism. Insert plate  200  further includes inner wall  208  that defines orifice  210 . Orifice  210  is sized to allow the cutting mechanism of a powered hand tool, such as, a router, saw, sander or the like, to extend above top surface  202  when the powered hand tool is mounted to insert plate  200 . Inner wall  208  forming orifice  210  includes ledge  212  extending radially inward from a lower section of inner wall  208 . Ledge  212  may be used to support a plate (not shown) with an orifice that more closely matches the size of the cutting mechanism of the hand tool mounted to insert plate  200  than orifice  210 . Such a plate may be fixed to insert plate  200  using screws or other suitable mechanism. Because different plates may be mounted within orifice  210  on ledge  212 , insert plate  200  is suitable for a variety hand tools and multiple size cutting mechanisms. For example, different plates may be used for different hand tools. As anther example, different plates may be used for routing bits of different sizes without removing the router from insert plate  200 . 
     Insert plate  200  supports a hand tool, and as well as work pieces that are worked on by the hand tool. Because of this, it is desirable for insert plate  200  to be formed from strong and durable materials. For example, insert plate  200  may be formed from suitable materials such as a metal, polymer, a filled resin, wood or the like. 
     As  FIG. 3  illustrates, support table  300  includes a generally planar top surface  302  and a generally planar bottom surface  304  oriented substantially opposite top surface  302 . Top and bottom surfaces  302 ,  304  are connected by peripheral wall  306 , which defines a generally rectangular perimeter of support table  300 . Support table  300  further includes inner wall  308  that defines orifice  310  sized to receive insert plate  200 . Orifice  310  is preferably sized such that inner wall  308  and periphery wall  206  form an intimate fit with each other. That is, it may be preferred that insert plate  200  is sized such that there is a minimal gap between periphery wall  206  and inner wall  308  once insert plate  200  is inserted in orifice  310 . This may facilitate the use of the hand tool on a work piece larger (e.g., in at least one dimension) than insert plate  200  by, for example, reducing the chances that the work piece catches on an edge of either insert plate  200  or support table  300 . Of course the leveling adjustment capability of mounting and leveling apparatus  100  also reduces the chances that the work piece catches on an edge of either insert plate  200  or support table  300 . 
     Support table  300  may be of any suitable size and may be supported by a support frame or other support structure. For example, support table  300  may be designed to rest on a work bench, and may thus include a relatively short support frame to suspend the support table  300  off of the work bench enough to provide clearance for a hand tool mounted to insert plate  200 . In other embodiments, support table  300  may include a frame which supports table  300  off of a floor at a desirable height. Support table  300  may include a durable and strong material, such as, for example, a metal such as aluminum or steel, wood, or the like. 
     It is generally desirable that top surface  302  of support table  300  and top surface  202  of insert plate  200  provide a substantially planar surface to support a work piece that is to be manipulated by the hand tool. Because insert plate  200  may experience wear during use of the hand tool, the thickness and/or thickness uniformity of insert plate  200  can change over the course of the lifetime of the insert plate. For example, insert plate  200  may wear substantially uniformly, and become thinner over substantially its entire area. As another example, a groove or depression corresponding to a common pattern of movement of a work piece across surface  202  of insert plate  200  may be formed over the course of time. Likewise, top surface  302  of support table  300  may also wear over time. 
     Regardless of the cause and/or evolution of any variation in the alignment of surface  202  of insert plate  200  with respect to surface  302  of support table  300 , it is desirable that this variation can be mitigated or fully corrected. Mounting and leveling apparatus  100  allows for straightforward and flexible adjustment of the position of surface  202  of insert plate  200  with respect to surface  302  of support table  300 . 
     For example, the combination of mounting bracket  102 , clamp screw  104  and leveling screws  106  allows precise adjustment of the distance between leveling plate  102  and surface  202 . Further, the use of at least two leveling screws  106  allows a user to adjust not only the distance between leveling plate  102  and surface  202 , but also the relative pitch of surface  202  of insert plate  200  with respect to leveling plate  102  (e.g., top surface  126  of leveling plate  102 ). As will be described in greater detail below, the configuration of mounting and leveling apparatus  100  allows precise positioning of leveling plate  102  relative to support table  300 . For example, mounting and leveling apparatus  100  may be used to align top surface  202  of insert plate  200  with surface  302  of support table  300  even if insert plate  200  becomes worn or warped over time. 
     As shown in  FIG. 3 , in one embodiment, a system including a support table  300  defining a generally rectangular orifice  310  and a generally rectangular insert plate  200  may beneficially employ four mounting and leveling apparatuses  100  to allow adjustment of the position of surface  202  with respect to surface  302  at four locations. Employing more than one mounting and leveling apparatuses  100  may allow greater adjustment flexibility to facilitate adjustment of a position of surface  202  with respect surface  302 . For example, utilizing more than one mounting and leveling apparatus  100  may allow correction for any warp or thickness gradation of insert plate  200 . In other embodiments, more than four or fewer than four mounting and leveling apparatuses  100  may be employed. 
     Mounting plate  102  couples to support table  300  via mounting screws  108   a ,  108   b ,  108   c  (collectively “mounting screws  108 ”), which extend through-holes  114   a ,  114   b ,  114   c  (collectively “holes  114 ”), respectively. Holes  114  may include substantially smooth sidewalls. Mounting screws  108  then threadably engage with mounting holes  312  of support table  300  to couple mounting bracket  102  with support table  300 . In other embodiments, mounting screws  108  may be self tapping screws, such as wood screws, that do not require threaded holes or even holes in support table  300 . While three mounting screws  108  are illustrated in the figures, in other embodiments, any useful number of mounting screws  108  may be utilized. For example, in some embodiments, the mounting bracket  102  may be coupled to the support table using at least one mounting screw  108 . 
     Mounting plate  102  may be generally triangular in shape, as illustrated in the figures. However, it will be understood that the shape of the mounting bracket  102  is not thus limited, and may include other shapes, such as, for example, rectangular, circular, elliptical, or any other useful shape. Mounting plate may be formed of a wide range of materials, including, for example, metal, polymer, filled resin, or the like. In some embodiments, mounting bracket  102  includes a filled resin, such as, for example, a glass filled resin. 
     In the illustrated embodiment, mounting bracket  102  also includes a protrusion  116 , best seen in  FIG. 1 . In the embodiment shown in the figures, protrusion  116  is shaped to register mounting bracket  102  with a corner  314  of the generally rectangular orifice  310  defined in support table  300 . To accomplish this, in the illustrated embodiment, the protrusion  116  includes edge  116   a  that is curved with a radius of curvature approximately equal to the radius of curvature of the corner  314  of orifice  310 . More specifically the protrusion  116  is formed by a first straight side  116   b  and a second straight side  116   c  and an arched corner  116   d . The first straight side  116   b  of the protrusion  116  is continuous with the arched corner  116   b  of the protrusion and the arched corner  116   d  of the protrusion  116  is continuous with the second straight side  116   c  of the protrusion  116 . In other embodiments corner  314  may have a different shape such as a right-angle; in any embodiment protrusion  116  may be configured to match the shape of corner  314 . Registering mounting bracket  102  to corner may substantially align holes  312  of support table  300  with holes  114  of mounting bracket  102  to facilitate insertion and threading of mounting screws  108 . 
     Rectangular orifice  310  is a straight-cut through-hole in support table  300 . Rectangular orifice  310  may be created using a jigsaw or other suitable cutting instrument. The support table orifice  310  defines a first straight side  310   a  and a second straight side  310  and an arched corner  310   c . The first straight side  310   a  of the support table orifice  310  is continuous with the arched corner  310   c  of the support table orifice  310  and the arched corner  310   c  of the support table orifice  310  is continuous with the second straight side  310   b  of the support table orifice  310 . Thus, the first and second straight sides  116   b  and  116   c  of the protrusion  116  and the arched corner  116   d  of the protrusion  116  extends into the support table orifice  310  and continuously engages the first and second straight sides  310   a  and  310   b  of the support table orifice  310  and arched corner  310   c  of the support table orifice  310 . In this manner, a kit including a set of mount and leveling apparatuses  100  and an insert plate  200  could be installed on any suitable table by cutting any suitable table to include orifice  310 . For example, such a kit may include a template for orifice  310 . 
     In other embodiments, mounting bracket  102  may not include a protrusion  116  to register the mounting bracket  102  to corner  314  of orifice  310 . In yet other embodiments, mounting bracket  102  may include a plurality of features which register mounting bracket  102  to corner  314  of orifice  310 . For example, mounting bracket  102  may include at least two smaller protrusions which together register mounting bracket  102  to corner  314  of orifice  310 . Further, in other embodiments, mounting bracket  102  may include protrusions or other features which register mounting bracket  102  to another location of orifice  310 , such as, for example, a location along an edge of orifice  310 . 
     As is best seen in  FIG. 1 , leveling screws  106  are threaded into holes  110   a  and  110   b  (collectively “holes  110 ”) from the direction of bottom surface  128  of mounting bracket  102 . As shown in  FIG. 1 , holes  110  and hole  112 , which is configured to receive clamp screw  104 , form a straight line. Furthermore, holes  110  are substantially equidistant from hole  112 . In other embodiments, holes  110  may not be substantially equidistant from hole  112 . Holes  110  may themselves be threaded, or may included a threaded inserts  124   a  and  124   b  molded into mounting bracket  102 . Threaded inserts  124   a  and  124   b  may include a highly durable and strong material, such as, for example, brass or steel. 
     Leveling screws  106  may be threaded through-holes  110  until each leveling screw  106   a  and  106   b  protrudes from top surface  126  of mounting bracket  102 . In this manner, leveling screws  106  are threaded through-holes  110  in the opposite direction that clamp screw  104  is threaded through-hole  112 . To accomplish the threading, leveling screws  106  may include suitable features to allow mating with a screw bit, such as a hex head bit, a Phillips bit, or the like. 
     Leveling screws  106  form contact sites on which insert plate  200  rests. Adjusting the length of each of leveling screws  106  that protrudes from surface  126  of mounting bracket  102 , then, likewise adjusts the distance between major surface  126  of mounting bracket  102  and bottom surface  204  of insert plate  200  at each point of contact. 
     Additionally, providing at least two leveling screws  106  in each mounting and leveling apparatus  100  allows a user to finely position insert plate  200  with respect to support table  300 . For example, utilizing two leveling screws  106  in each apparatus  100  may allow a user to correct the angle at which insert plate  200  is oriented at the location of each apparatus  100 . In contrast, use of a single leveling screw  106  at each apparatus  100  would not allow this fine adjustment or twisting of insert plate  200  to restore its flatness in the event it became warped. While  FIG. 1  illustrates two holes  110 , in other embodiments, may include more than two holes  110  and a corresponding number of leveling screws  106 . The use of at least two leveling screws  106  may provide a more secure support of insert plate  200  than a single leveling screw  106  would allow. Likewise, in alternative embodiments, more than one hole  112  and corresponding clamp screw  104  may be utilized. 
     As is best seen in  FIG. 2 , clamping screw  104  is inserted into hole  216  of insert plate  200  from the side of surface  202 . In the illustrated embodiment, hole  216  includes a countersunk opening in surface  202 , which may minimize the extent to which clamping screw  104  protrudes from surface  202 . Clamp screw  104  is then threaded through-hole  112  of mounting bracket  102 . Hole  112  may itself be threaded, or may included a threaded insert  122  molded into mounting bracket  102 . Threaded insert  122  may include a highly durable and strong material, such as, for example, brass or steel. Clamping screw  104  couples insert plate  200  to mounting bracket  102  and preferably firmly contacts insert plate  200  and leveling screws  106 . Once clamping screw  104  is sufficiently tightened, the mounting and leveling apparatus  100  substantially prevents movement of insert plate  200  with respect to support table  300 . While a single clamping screw  104  for each mounting and leveling apparatus  100  is illustrated in the figures, in other embodiments, more than one clamping screw  104  may be utilized. 
     The support table  300  may further incorporate a fence system. One exemplary fence system includes a universal machinery fence system, as described in further detail in U.S. Patent Application Publication No. 2006/0248998, which is incorporated herein by reference in its entirety. Generally, the universal machinery fence system has a rail for attachment to a support table  300  of a workpiece manipulation machine and the rail defines a track. A clamp block is releasably assembled to the rail with surfaces that mate with the track of the rail to guide the clamp block linearly along the rail. The clamp block includes a fastener for securing the position of the clamp block along the rail. The system includes a fence for guiding a workpiece into a workpiece manipulation tool, the fence being fixed to the clamp block. The clamp block and fence can be used on, for example, a band saw, a router, a table saw, a drill press, or the like, by substituting the rail for a rail of a different cross-sectional shape. 
     A kit may be useful to allow a craftsman to mount an insert plate to a homemade support table. A kit for mounting an insert plate to a support table may include at least two mounting and leveling apparatuses, such as mounting and leveling apparatus  100  ( FIG. 1 ). For example, a kit may include exactly four mounting and leveling apparatuses to facilitate mounting a rectangular insert plate to a support table. In some embodiments, as kit may include the insert plate itself. Such a kit may also include a template for forming an orifice for the insert plate in the homemade support table. 
     A kit may optionally include a screw driver for the screws in the mounting and leveling apparatuses. For example, the screw driver may be a Phillips screw driver, a flathead screw driver, an allen wrench, or a square drive. In embodiments having screws with different screw head configurations, a kit may include a screw driver for each screw head configuration. In one embodiment, a kit may include an alien wrench and a square drive. 
     Various embodiments of the invention have been described. These and other embodiments are within the scope of the following claims.