Patent Publication Number: US-2023150045-A1

Title: Extendible outfeed accessory for a table saw

Description:
BACKGROUND 
     This patent application relates to table saw accessories and more particularly table saw outfeed tables. 
     Table saws are indispensable tools for woodworkers and come in a variety of sizes and configurations. For example, table saws come in compact sizes for field use by contractors, for example, and in larger, non-portable cabinet type units for production shops. Regardless of size of the table saw, the sheet stock that is being cut is often much larger than the tabletop thereof, often requiring an outfeed table to manage unwieldy stock. Outfeed tables, however, have limited use and may not be an acceptable solution for a small shop. Folding outfeed tables exist, but those too have limitations, including flimsy construction and/or difficulty in assembly when necessary to handle large sheet stock. Accordingly, there is a need for a table saw accessory for supporting outfeed that is not so limited. 
     SUMMARY 
     In one aspect, a table saw accessory is provided that includes: an outfeed support having at least one surface for supporting material fed through the table saw beyond an end thereof; a telescopic section having a proximal end and a distal end, and configured to extend outward from the end of the table saw, wherein the outfeed support is coupled to the telescopic section at the end thereof; and a connection system for attaching the accessory to the table saw, wherein the connection system is coupled to the telescopic section at the proximal end thereof. 
     In one embodiment, the telescopic section is configured to extend outward as the material extends beyond the end of the table saw. 
     In one embodiment, the outfeed support is configured to rotate about an axis parallel to a tabletop of the table saw as the telescopic section extends outward. 
     In one embodiment, the telescopic section comprises at least one spatial scissor mechanism. 
     In one embodiment, the at least one spatial scissor mechanism comprises a plurality of hinged links pivotally coupled to each other. 
     In one embodiment, the at least one spatial scissor mechanism comprises a plurality of pairs of hinged links pivotally coupled to each other, the plurality of pairs of hinged links connected to each other in series such that extension of one of the pair of hinged links translates to an outward movement in another of the pair of hinged links. 
     In one embodiment, the plurality of pairs of hinged links are dimensioned between joints thereof so that outward expansion in each of the plurality of the pair of hinged links is equal. 
     In one embodiment, the at least one spatial scissor mechanism comprises a first and a second spatial scissor mechanism, each comprising a plurality of hinged links pivotally coupled to each other, and at least one lateral strut interconnecting a joint associated with the plurality of hinged links of the first spatial scissor mechanism with a joint associated with the plurality of hinged links of the second spatial scissor mechanism. 
     In one embodiment, the at least one spatial scissor mechanism comprises a plurality of hinged links pivotally coupled to each other, the connection system comprising a top and a bottom connector interface element, each pivotally attached to one of the plurality of hinged links. 
     In one embodiment, the top the interface element comprises a cylindrical structure and wherein the connection system further comprises a pin that passes through the cylindrical structure of the top interface and that fixedly attaches the top interface element with respect to vertical movement to the table saw. 
     In one embodiment, the connection system is configured for the bottom interface element to move vertically relative to the table saw. 
     In one embodiment, the bottom interface element is fixed with regard to horizontal movement. 
     In one embodiment, the bottom interface element comprises a cylindrical structure and wherein the pin passes through the cylindrical structure of the bottom interface. 
     In one embodiment, the outfeed support comprises at least one curved section, which, when the accessory is in a retracted position, the at least one curved section extends vertically upward to cross a plane of a tabletop of the table saw. 
     In one embodiment, the outfeed support comprises a first planer section adjacent to the curved section, and wherein the outfeed support is configured to rotate about an axis parallel to the tabletop of the table saw and for the first planer section to flatten as the telescopic section extends outward. 
     In one embodiment, the outfeed support comprises a second planer section adjacent to the first planer section and at an angle relative thereto to act as a stop for the material. 
     In another aspect, a table saw accessory is provided that includes: an outfeed support having at least one surface for supporting material fed through the table saw beyond an end thereof, the outfeed support comprising at least one curved section, which, when the accessory is in a retracted position, the at least one curved section extends vertically upward to cross a plane of a tabletop of the table saw; a telescopic section having a proximal end and a distal end, and configured to extend outward from the end of the table saw as the material extends beyond the end of the table saw, the outfeed support coupled to the telescopic section at the end thereof, wherein the telescopic section comprises a plurality of pairs of hinged links pivotally coupled to each other and wherein the plurality of pairs of hinged links are connected to each other in series such that extension of one of the pair of hinged links translates to an outward movement in another of the pair of hinged links; and a connection system for attaching the accessory to the table saw, wherein the connection system is coupled to the telescopic section at the proximal end thereof. 
     In one embodiment, the outfeed support is configured to rotate about an axis parallel to the tabletop of the table saw as the telescopic section extends outward. 
     In one embodiment, the outfeed support comprises a first planer section adjacent to the curved section, and wherein the outfeed support is configured for the first planer section to flatten as the telescopic section extends outward. 
     In one embodiment, the outfeed support comprises a second planer section adjacent to the first planer section and at an angle relative thereto to act as a stop for the material. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG.  1    is a perspective view showing a table saw with an extendible outfeed accessory according to at least one of the embodiments of the accessories disclosed herein attached thereto and disposed in a retracted position. 
         FIG.  2    is a perspective view showing a table saw with an extendible outfeed accessory according to at least one of the embodiments of the accessories disclosed herein attached thereto and disposed in an extended position. 
         FIGS.  3 - 4    are perspective views showing an outfeed support portion of the extendible outfeed accessory according to at least one of the embodiments of the accessories disclosed herein. 
         FIGS.  5 - 6    are perspective views showing the connector interface elements portion for the extendible outfeed accessory according to at least one of the embodiments of the accessories disclosed herein in retracted and extended positions, respectively. 
         FIG.  7    is a side view showing an exemplary connection system for attaching the extendible outfeed accessory to a table saw. 
     
    
    
     DETAILED DESCRIPTION 
     The present application provides a table saw outfeed extension accessory which overcomes some or all the drawbacks associated with prior attempted solutions in the art. Although the accessory may be discussed herein in relation to a certain type of table saws, it is understood that the accessory may be applied to various types of circular table saws, such as a cabinet, contractor types, etc., as well as non-circular saw type tools, such as band saws, scroll saws, router tables, workbenches, assembly tables, etc. Accordingly, the system is not limited for use on any one type of tool that includes a table or tabletop. 
     Referring to  FIG.  1   , a table saw  100  generally includes a tabletop  102  and a base  104  to which the tabletop  102  is affixed and supported thereby. The tabletop  102  has a left side  106  and a ride side  106 ′ (opposite the left side  106 ). The left and right sides  106 ,  106 ′ may be parallel to each other. The tabletop  102  further includes a front or proximal end  108  and back or distal end  110  (opposite the front  108 ). The front and back  108 ,  110  may be parallel to each other and may be generally perpendicular to the sides  106 ,  106 ′. The tabletop  102  preferably includes therein a slot through which the saw blade  112  protrudes, such as the circular saw blade shown. The saw blade  112  is preferably retractable relative to the top  102 . Material or stock  116  that is being cut is placed on the top  102  and while the saw blade  112  is rotating, the user pushes the material  116  through the blade  112 , as shown. The table saw  100  may include an extendible outfeed accessory  114  for supporting the outfeed as the material  116  extends beyond the back  110  of the tabletop  102 . The outfeed accessory  114  may be attached to either side  106 ,  106 ′, and/or the front and back ends  108 ,  110 . 
     Referring to  FIG.  2   , in one embodiment, the accessory  114  includes an outfeed support, a telescopic section attached at one end to the outfeed support, and a connection system attached to the other/opposite end of the telescopic section for attaching the accessory to the base  104  of the table saw  100 . The outfeed support  200  generally provides one or more surfaces that supports the material  116  as the material  116  is pushed beyond the back end  110  of the table saw  100 . The telescopic section generally extends the outfeed support distally as the material  116  is pushed beyond the back end  110  of the table saw  100 . Preferably, the support  200  is coupled to the telescopic section at the distal end thereof and is configured to rotate about an axis parallel to the tabletop  102  as the material  116  is pushed beyond the back end  110  of the table saw  100  and as the telescopic section extends distally. The connection system connects the telescopic section to the base  104  and/or the tabletop  102  of the table saw  100 . 
     The telescopic section may provide the desired functionality, i.e., extensibility, in a variety of ways. In a preferred embodiment, the telescopic section includes at least one or preferably at least two spatial scissor mechanisms (a left scissor mechanism and a right scissor mechanism, as shown), which each includes a pair of hinged links  206 ,  206 ′ pivotally coupled to each other. The hinged links  206 ,  206 ′ are preferably connected in series at the ends thereof to at least one or a plurality of other pairs of hinged links, interconnected such that extension of one of the pair of hinged links  206 ,  206 ′ translates to a distal movement in each of the other pair of hinged links. The plurality of hinged links may be dimensioned between joints equally so that translation or distal expansion is equal in each of the pair of hinged links  206 ,  206 ′. 
     The left and right scissor mechanisms are preferably coupled to each other with one or more lateral struts  204 ,  204 ′,  204 ″ that maintain the distance between equivalent pairs of hinged links on the opposite scissor mechanism. In one embodiment, the telescopic section includes one or more of a bottom strut  204 , a top strut  204 ′, and/or middle strut  204 ″. The bottom struct interconnects the hinged links at the bottom joint, the middle strut  204 ″ interconnects the hinged links at the intersection thereof, and the top struct  204 ′ interconnects the hinged links at the top joint and the top strut may further be disposed at an elevation sufficient to support the material  116  as it is fed past the back end  110  of the tabletop  102 , as shown. In either event, the telescopic section terminates proximally with a connection system interface, which preferably includes a top and bottom connector interface elements  202 ,  202 ′, which allow the top and bottom links of the hinged links to move vertically relative to each other as the telescopic section extends outward from the tabletop  102 , as shown between  FIG.  1    and  FIG.  2   . 
     Referring to  FIGS.  3 - 4   , the outfeed support  200  may take a variety of shapes. For example, the outfeed support  200  may simply be a cylindrical, oval, rectangular, and/or a square bar or similar shape with a surface located at an elevation approximately as that of the tabletop  102  to support the material  116 . Similarly, the outfeed support  200  may be a flat panel that is installed to be essentially parallel and/or in the same plane as that of the tabletop  102 . If attached directly to the top joint, the outfeed support  200  may, depending on the means for attaching the accessory  114  to the table saw  100 , lower as the scissor mechanism extends outward. In this regard, the support  200  may be a cam (i.e., have a ramped and/or curved support surface, as shown) or operate on a cam mechanism that rotates and that maintains the support surface essentially in the same plane as the tabletop  102 , for example, accounting for manufacturing tolerances, as the material  116  is fed through the saw  112  and as the accessory extends outward. 
     Alternatively or additionally, the outfeed support  200  may include at least one upwardly curved section  302 , which in the retracted position extends vertically upward to cross the plane of the tabletop  102  and/or the material  116 , as shown. The curved section  302  may be followed distally with a first planer section  304  and then a second planer section  306 . Preferably, the outfeed support  200  is coupled to the distal end of the telescopic section such that the outfeed support  200  rotates about an axis  312  parallel to the tabletop  102  and/or perpendicular to the saw blade  112  as the outfeed support  200  extends distally. For example, the outfeed support  200  may be fixedly attached to the top joint of the hinged links  206 ,  206 ′ so that as the vertical orientation of the hinged links  206 ,  206 ′ flattens, so does the outfeed support  200  which as a result effectively pivots about the axis between the middle joints of the effective hinged links  206 ,  206 ′ to which the outfeed support  200  is attached. In this regard, the accessory  114  may be configured so that the curved section  302  pivots as the accessory  114  extends so that the curved section  302  does not interfere with the material  116  as the material  116  is fed past the back end  110  of the tabletop  102 , as shown in  FIG.  2   . Alternatively, the accessory  114  may be configured to extend distally when the material  116  touches the curved section  302  and flattens as the accessory  114  extends outward. Moreover, the accessory  114  may be configured such that the first planer section  304  flattens to the point that it becomes essentially level (e.g., +/−5 degrees) at full extension, preferably at the same level as the tabletop  102 . The second planer section  306  preferably acts as a stop to prevent the material  116  from being fed beyond the distal end of the outfeed support  200  when fully extended. The accessory may include a counterweight or a post below the accessory and that moves outwardly from the table saw  100  along with the outfeed support  200  to prevent the table saw  100  from tipping as the material is fed through the saw  112 . 
     The telescopic extension may be operated manually and/or may be automated so that the outfeed support will extend distally to provide support for the material  116  as it passes beyond the back end  110  of the tabletop  102 . The latter may be accomplished with one or more sensor that determines the extent that the material  116  has moved beyond the back end  110  and/or the proximal end of the outfeed support  200 , and sends a signal to a controller/motor that causes the outfeed accessory/telescopic section to extend accordingly. The sensor may be light a sensor that is located on the accessory and/or the outfeed support, in-line with the saw blade  112 , so that when the material  116  covers the light sensor, the controller/motor causes the outfeed accessory/telescopic section to extend until the light sensor is once again uncovered. Several light sensors, for example, along the proximal edge of the outfeed support  200 , may be used for the controller/motor to determine based thereon that the material has been removed completely from the outfeed support  200  and thus cause retraction of the outfeed accessory/telescopic section in response thereto. This functionality may also be achieved with one or more pressure sensors, for example, that sense pressure or weight on the outfeed support  200  as the material  116  is fed through the saw blade  112  and that signals the controller to extend proportionally as the pressure/weight of the material  116  on the sensor increases as the material  116  is fed through the saw blade  112 . When pressure/weight is removed, the outfeed support  200  may return to the retracted position automatically. 
     Referring to  FIGS.  5 - 6   , in one embodiment, the connector interface elements for the extendible outfeed accessory  114  includes a top interface element  502  and a bottom interface element  504 , each attached to one of a top joint and a bottom joint of the hinged links  206 ,  206 ′, as shown. As shown between  FIGS.  5  and  6   , as the accessory  114  extends distally, the top and bottom joints of the scissor mechanism move vertically closer together and the top and bottom interface elements  502 ,  504  therefore also move vertically relative to each other. In a preferred embodiment, the top interface element  502  is fixed both against vertical and horizontal movement relative to the table saw  100  whereas the bottom interface  504  element is free to move vertically, as shown, but preferably otherwise fixed. The interface elements  502 ,  504  are generally pivotally connected to the ends of the hinged links  206 ,  206 ′, as shown. At the opposite end of thereof, the interface elements  502 ,  504  may include cylindrical structure that mates with or receives corresponding structure attached to the table saw  100  (collectively, the connection system). 
     Referring to  FIG.  7   , an exemplary embodiment of the connection system is shown. The connection system includes top and bottom interface elements  502 ,  504 , which have collinear cylindrical structures that mate with a pin  908 . The pin  908  may be fixedly attached to the table saw  100  and more specifically the tabletop  102 . In a preferred embodiment, the tabletop  102  includes therein a recessed hole to accept the head  902  of the pin  908  so that the top of the pin  908  is flush with the tabletop  102 , as shown. The pin  908  may include a threaded section for fixing the top interface element  502  to the table saw  100  and/or tabletop  102 . The head  902  may include a slot therein to accommodate a screwdriver. The top interface element  502  may include corresponding threads or a threaded nut  910  may be provided to fix the top interface element  502  relative to the top  102  for use. The pin  908  preferably has sufficient length for the bottom interface element  504  to move vertically in a collinear path provided by the pin  908  while preventing horizontal movement along the range of vertical movement of the bottom interface element  504 . The system may also include a support  904  that attaches to the table saw base  104  and that has a flange  906  extending therefrom with a hole therein to accommodate and provide support for the pin  908  against horizontal movement. The flange  904  may be installed between the top and bottom interface elements  502 ,  504 , as shown, or below both elements  502 ,  504 . 
     While the foregoing has been described in some detail for purposes of clarity and understanding, it will be appreciated by one skilled in the art, from a reading of the disclosure, that various changes in form and detail can be made without departing from the true scope of the invention.