Patent Publication Number: US-11648659-B2

Title: Work support

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application claims the benefit of U.S. Provisional Patent Application No. 62/913,709 entitled “WORK SUPPORT” and filed on Oct. 10, 2019 for Jared W. Hanlon, which is incorporated herein by reference. 
    
    
     FIELD 
     This invention relates to work stands, and more particularly relates to portable work stands that are adaptable for many uses. 
     BACKGROUND 
     Work support stands are generally used for supporting, cutting, or shaping work pieces such as construction lumber, and other materials. Some work support stands are portable and configurable for supporting power tools, or functioning as a sawhorse. A support assembly includes supports for connecting the power tool to the work support stand. Miter saws are one such power tool that are often used with work support stands. The work support stand typically positions the miter saw at a height that matches the user&#39;s upper body so that the user does not have to kneel to use the miter saw. Many work support stands offer this functionality, but often times the mechanisms to support the features of portability and securely mounting the miter saw result in a bulky work support stand that is difficult to ship, display, and store once purchased. 
     SUMMARY 
     Disclosed is a work support having an extendable support beam for spanning between a pair of leg assemblies. The extendable support beam includes one or more elongated rails having a first end, a second end, an upper edge, a lower edge, a middle portion disposed between the upper edge and the lower edge, where the upper edge and the lower edge each extend away from the middle portion and form a channel having an interior surface and an exterior surface, and a t-track extending longitudinally along the interior surface. 
     In certain examples, the elongated rail comprises a first elongated rail and a second elongated rail. The second elongated rail may be identical to the first elongated rail. The extendable support beam also includes, in certain examples, a central member configured to slidingly engage the interior surface of each of the first elongated rail and the second elongated rail such that the first elongated rail and the second elongated rail are slidable along a longitudinal axis to one of extend or decrease an overall length of the extendable support beam. 
     In certain examples, the extendable support beam includes a biased detent positioned at an end of the central member, where the biased detent is configured to lock into an opening in the first elongated rail to prevent the central member from sliding past either the first end or the second end of the first elongated rail. The upper and/or lower edges may include an inwardly extending member configured to engage a mount. 
     The work support, in certain examples, includes the extendable support beams and a leg mount disposed between the pair of elongated rails, and a pair of legs pivotally coupled with the leg mount and moveable between a storage position where the pair of legs are secured within a cavity, and a working position. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In order that the advantages of the invention will be readily understood, a more particular description of the invention briefly described above will be rendered by reference to specific embodiments that are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the invention and are not therefore to be considered to be limiting of its scope, the invention will be described and explained with additional specificity and detail through the use of the accompanying drawings, in which: 
         FIG.  1    is a perspective view diagram illustrating one embodiment of a work support in accordance with examples of the present disclosure; 
         FIG.  2    is another perspective view diagram illustrating one embodiment of the work support in accordance with examples of the present disclosure; 
         FIG.  3    is a perspective view diagram illustrating one embodiment of a leg bracket in accordance with embodiments of the present disclosure; 
         FIG.  4    is a cross-sectional perspective view diagram illustrating one embodiment of the work support in accordance with embodiments of the present disclosure; 
         FIG.  5    is a perspective view diagram illustrating another embodiment of the work support in accordance with embodiments of the present disclosure; 
         FIGS.  6   a  and  6   b    depict the cross-sectional profile of the rails, in accordance with embodiments of the present disclosure; 
         FIG.  7    is a perspective view diagram illustrating one embodiment of a central member of an extendable rail system in accordance with embodiments of the present disclosure; 
         FIG.  8    is a side view diagram illustrating one example of slidable rails in accordance with examples of the present disclosure; 
         FIGS.  9   a  and  9   b    depict embodiments of a low-profile tool mount in accordance with examples of the present disclosure 
         FIG.  10    is a perspective view diagram of a portion of the tool mount in accordance with embodiments of the present disclosure; 
         FIG.  11    is a diagram illustrating one embodiment of a work support in accordance with embodiments of the present disclosure; 
         FIG.  12   a    is a perspective view diagram illustrating one embodiment of a side handle in accordance with examples of the present disclosure; 
         FIGS.  12   b    and  13  are perspective view diagrams illustrating one embodiment of the end handle in accordance with examples of the present disclosure; 
         FIG.  14    is a perspective view diagram illustrating one example of a leg assembly (leg mount and legs), in accordance with examples of the present disclosure; 
         FIG.  15    is a perspective view diagram illustrating one example of a saw-horse configuration of the work support in accordance with examples of the present disclosure; 
         FIG.  16    is a schematic block diagram illustrating one embodiment of the work support in accordance with examples of the present disclosure; and 
         FIGS.  17   a - 17   e    are cross-sectional diagrams illustrating rails, according to examples of the subject disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     Reference throughout this specification to “one example,” “an example,” or similar language means that a particular feature, structure, or characteristic described in connection with the example is included in at least one example of the present disclosure. Appearances of the phrases “in one example,” “in an example,” and similar language throughout this specification may, but do not necessarily, all refer to the same example. Similarly, the use of the term “implementation” means an implementation having a particular feature, structure, or characteristic described in connection with one or more examples of the present disclosure, however, absent an express correlation to indicate otherwise, an implementation may be associated with one or more examples. 
       FIG.  1    is a perspective view diagram illustrating one embodiment of a work support  100  in accordance with examples of the present disclosure. The work support  100 , as will be discussed in greater detail below, is configurable for many uses, including but not limited to, a miter saw stand, a low-profile miter saw stand, a sawhorse, and a clamping table. The work support  100 , in certain embodiments, is manufactured of a combination of metal and/or plastic components. In particular, the support beams (formed of one or more rails  102 ) that extend between the pairs of legs  104 , may be aluminum (or an alloy thereof) and extruded. The rails  102  are spaced apart a distance that allows for the legs  104  to collapse and fold in between the rails  102 . This beneficially allows for the entire work support  100  to be packaged efficiently, and displayed neatly on a store&#39;s shelves. 
       FIG.  2    is another perspective view diagram illustrating one embodiment of the work support  100  in accordance with examples of the present disclosure. In certain embodiments, the rails  102  are configured to receive removable saw mounts  202 . In other embodiments, the saw mounts  202  are configured to couple with other tools including, but not limited to, grinders, sanders, portable table saws, planers, etc. The saw mounts  202  are configured with an inner jaw that mates to an exterior surface of a rail (see  FIG.  9   , see also  102  of  FIG.  1   ). A lever of the saw mount  202  engages the inner jaw and causes the inner jaw to clamp onto the rails  102 . 
     Also depicted in  FIG.  2   , is a leg mount  204 . In certain embodiments, the leg mount  204  (see also  FIG.  14   ) couples to interior surfaces of the rails  102  and rotatably couples the legs  104  to the leg mount  204 . The leg mount  204 , as will be described below in greater detail with reference to  FIG.  3   , includes openings for receiving a slidable board support  206 . The leg mount  204  couples to the rails  102  and torsionally stiffens the work support  100 . 
     The work support  100 , in certain embodiments, includes side handles  208  and end handles  210 . The side handles  208  extend outward laterally from one of the rails  102  and may be coupled to a bottom surface of the rail  102  with fasteners (not shown). The end handles  210  engage both of the rails  102  and, in certain embodiments, insert into a channel formed by the rails  102 . Fasteners may secure each end handle  210  to the rails  102 . 
       FIG.  3    is a perspective view diagram illustrating one embodiment of a leg bracket  300  in accordance with embodiments of the present disclosure. The leg bracket  300 , in certain embodiments, may be formed of a durable polymer material, or alternatively, a metal alloy. The leg bracket  300  extends transversely between the rails  102  from a first end  302  to a second end  304 . Each end  302 ,  304  of the leg bracket  300  is formed to mate with the interior surface of the rail  102 . In the depicted embodiment, this shape is generally a C-shape and includes a T-member or protrusion  306  that mates with a T-shaped channel in the rail. It is contemplated that other shapes may be implemented that slidingly lock one end of the leg bracket  300  to one of the rails  102 . 
     In certain embodiments, the leg bracket  300  includes openings  308  for the board support  206  (e.g., an extendable board support) to pass through the leg bracket. Additionally, the leg bracket  300  includes leg channels  310  for receiving and securing the legs  104  when the legs are in a collapsed, storage position. A rotatable butterfly handle  312  with a twist-lock mechanism secures the legs  104  in the storage position. The rotatable butterfly handle  312  is also configured to lock the slidable board support  206  in any position between a fully extended position and a fully retracted position. This may be accomplished with an off-set cam inside the butterfly handle  312  that engages the board support  206  and prevents movement. 
       FIG.  4    is a cross-sectional perspective view diagram illustrating one embodiment of the work support  100  in accordance with embodiments of the present disclosure. As depicted, the rails  102  have a C-shaped cross-sectional profile that may be formed of extruded aluminum. The board support  206  is configured to slide into and out of the work support  100  to accommodate different length boards. In certain embodiments, the rails are extendable. In alternative embodiments, the rails are of fixed length. 
       FIG.  5    is a perspective view diagram illustrating another embodiment of the work support  100  in accordance with embodiments of the present disclosure. The work support  100 , in the depicted embodiment, may include a removable work surface  502 . The work surface  502 , in certain embodiments, is formed of sheet metal and includes an array of openings. The openings are useful for many operations, including attachment of clamping devices, etc. The work surface  502  may also be utilized as a welding table. Beneficially, the rails  102  are spaced apart a distance selected to accommodate multiples of pieces of lumber, for example, two 2×4 pieces, as will be described in greater detail below. 
       FIGS.  6   a  and  6   b    depict the cross-sectional profile of the rails  102 , in accordance with embodiments of the present disclosure. In certain embodiments, the cross-sectional profile of each rail  102  is generally C-shaped. However, other cross-sectional profiles are contemplated (see  FIG.  17   ). An interior surface  602  of the rail  102 , in certain examples, includes a T-channel or track  604 . The T-track  604  is useful for laterally securing brackets, members, etc., to the rail  102 . As used herein, a longitudinal axis refers to an axis that extends from one end of the rail to the opposing end of the rail, and a lateral axis  606  extends outward laterally in a direction generally perpendicular to the longitudinal axis. As such, extending laterally from the rail  102  refers to extending in a direction along the lateral axis  606 . 
     The t-track  604  is formed of an additional pair of inwardly extending members  610  that extend laterally from the interior surface  602  of the rail  102 . In other examples, the thickness of the rail  102  is increased and the t-track  604  is formed within that thickness. Other geometric shapes are contemplated that allow for the movement of a component longitudinally along the rail, but that prevent lateral movement. An upper edge  612  and a lower edge  614  of the rail  102 , in certain embodiments, include an inwardly extending member  608 . Stated differently, each edge of the C-shape cross-sectional profile has a serif-like projection that extends toward the extending member  608  of the opposing edge. These inwardly extending members  608  are useful for locking components, such as a low-profile tool mount, as will be described below in greater detail (see  FIG.  9   ). Alternatively, the C-shaped profile terminates at each edge  612 ,  614  with members that extend substantially coaxially. 
     Disposed between the upper edge  612  and the lower edge  614  is a middle portion  609 . The middle portion  609  extends between the upper edge  612  and the lower edge  614 , and forms the interior surface  602  and the exterior surface  603 . The t-track  604  may be formed on one or more of the interior surface  602  or the exterior surface. The rail  102 , in certain examples, has a first end  605  and a second end  607 . The t-track  604  may extend from the first end  605  to the second end  607 . In other examples, the t-track  604  extends from an area near the first end  605  to an area near the second end  607 . 
     In a further embodiment, openings  611  are formed in the surface of the rail  102  for mounting components, such as the side handles  208  and end handles  210 . The openings  611 , in certain examples, receive fasteners, or alternatively, protrusions from the component that mate to the rail  102 . 
     In certain examples, the t-track  604  may be formed on the exterior surface of the rail  102 , as depicted by the dotted lines. This, beneficially, allows for the attachment of various accessories, including, but not limited to, moveable/slidable handles, flip-up top, clamping bench, etc. 
       FIG.  7    is a perspective view diagram illustrating one embodiment of a central member  700  of an extendable rail system in accordance with embodiments of the present disclosure. The extendable central member  700 , in certain examples, is formed with a generally C-shaped cross-sectional profile configured to engage an interior surface of the rail  102 . The central member  700 , in certain examples, includes a fastener for securing the central member  700  to one of the rails  102 . In certain examples, the fastener is a screw, or alternatively a depressible detent  704  that is biased by a mounting member  706 . The detent  704  is configured to pop into an opening in the rail and prevent the rail  102  from sliding past the end of the central member  700 . 
     The central member  700  engages the interior surface of an extendable rail  102  and also an adjacent extendable rail  102 . As such, the central member  700  slidingly engages a pair of rails  102  to coaxially align the rails  102 .  708  depicts the longitudinal axis. 
       FIG.  8    is a side view diagram illustrating one example of slidable rails  102  in accordance with examples of the present disclosure. The central member  700  engages and coaxially aligns a pair of adjacent rails  102 . The central member  700 , in certain examples, includes fasteners that engage the T-track  604  of the rails. As depicted, the central member  700  is formed of a resilient polymer material, such as ABS, while the rails  102  are formed of an extruded aluminum allow. In other examples, the central rail  700  is formed of the same material as the rails  102 . 
       FIGS.  9   a  and  9   b    depict embodiments of a low-profile tool mount  900  in accordance with examples of the present disclosure. The low-profile tool mount  900  is configured to couple to the interior surface of the rails  102 . In contrast with common tool-mount systems for work supports that mount to the exterior surface of a rail, the low-profile tool mount  900  includes engaging members  902  that provide a clamping force in a direction towards the edges of the tool mount  900 , as depicted by arrows  904 . Conversely, common tool mounts provide a clamping force directed inwards that clamps on exterior surfaces of the rails. The engagement members  902  are configured to mate with a portion of the interior surface of the rails  102 . 
       FIG.  10    is a perspective view diagram of a portion of the tool mount  202  in accordance with embodiments of the present disclosure. As described above with reference to  FIG.  2   , the tool mount  202 , in certain examples, includes engagement members that mate with exterior surfaces of the rails  102 . These engagement members  1002  provide a clamping force that is directed inward, or towards the opposing engagement member (not shown). The engagement members  1002  of the tool mount  202  may include surfaces configured to engage with the exterior surfaces of the rail  102 . In the depicted example, the engagement members  1002  include a general C-shape for mating with the exterior surfaces of the rail  102 . At least one of the engagement members  1002  is positionable, and lockable in a predetermined location. A lever  1004  may include a cam-type mechanism that creates a clamping force on the rails  102 . 
       FIG.  11    is a diagram illustrating one embodiment of a work support  1100  in accordance with embodiments of the present disclosure. In certain embodiments, the work support  1100  is configured to receive board members to form a disposable work surface. Often times it is necessary to cut a board on a work support, however, the act of cutting the board destroys the work surface because a cutting blade must extend entirely through the board to complete the cut. The cutting blade then also extends slightly into a work surface of a sawhorse, which damages the sawhorse. Beneficially, the work support  1100  is configured to receive a board member  1102  between the rails  102 . The board member  1102  is supported by, in certain examples, the leg mount  204  or leg bracket  300 . 
     The leg mount  204  and the leg bracket  300  cause the board member  1102  to extend upward above a top surface of the rails  102 . Accordingly, a worker may then cut another piece of board on top of the board member  1102  without damaging the rails  102 . The board member  1102  serves as a sacrificial work surface. In certain embodiments, the rails  102  are spaced apart a distance selected to receive a common 2×8 board member, or a pair of 2×4 board members. The board member  1102 , in certain examples, is fastenable to either of the leg mount  204  or the leg bracket  300 . In other examples, an end bracket engages the end of the board member  1102 . In certain examples, the board members  1102  are held in place by a slight friction fit with the rails  102 . 
       FIG.  12   a    is a perspective view diagram illustrating one embodiment of a side handle  208  in accordance with examples of the present disclosure. The side handle  208 , in certain examples, is configured to fasten to a side of a rail  102 . The side handle  208  includes a mounting surface  1202  having a shape to mate with the exterior bottom surface of the rail  102 . Openings  1204  in the side handle  208  are configured to receive a fastener that couples the side handle  208  to the rail  102 . 
     In certain examples, the side handle  208  is formed with openings  1206  and  1208 . Opening  1206  is configured to receive a user&#39;s hand. Opening  1208  is configured to receive a tool. For example, a clip of a tape measure may be inserted into opening  1208 . Additionally, the top surface of the side handle  208  may have a raised portion  1210  that is sized and configured to receive a board member. A board member may be placed horizontally across two side handles  208  in a manner similar to line  1212 . Raised portion  1214  maintains the position of the board member on the side handle  208 . This is useful for storing scrap pieces of wood. In certain examples, the opening  1206  is sized to receive a board member and hold the board member in a substantially vertical position, as opposed to the previously described horizontal position. 
       FIGS.  12   b    and  13  are perspective view diagrams illustrating one embodiment of the end handle  210  in accordance with examples of the present disclosure. The end handle  210  is configured to insert into ends of the rails  102  and space apart the rails  102  a predetermined distance. The distance, as described above, is selected to accommodate a board member or multiples of board members. In other words, the predetermined distance is a multiple of 3.5 inches (the actual width of a 2×4). In certain examples, the board member is a standard 2×8 piece of lumber. The ends  1302  of the side handle  210  are configured with a C-shaped cross-sectional profile configured to slidingly engage the interior surface of the rails  102 . Each side handle  210  includes a pair of ends  1302  for engaging a pair of rails  102 . Openings  1304  in the ends  1302  of the rails are configured to align with openings in the rails  102 , through which fasteners may pass and secure the end handles  210  to the rails. Each work support  100 , in certain examples, includes a pair of end handles  210  at opposing ends of a pair of rails  102 . The end handle  210  may be provided with any configuration of ends  1302  to match any cross-sectional profile of rail  102 . In additional examples, the ends  1302  of the end handle  210  may be configured with a T-shape insert for mating with the T-track of the rails  102 . 
       FIG.  14    is a perspective view diagram illustrating one example of a leg assembly (leg mount  204  and legs  104 ), in accordance with examples of the present disclosure. The leg mount  204 , as described above, is shaped with ends configured to mate to the interior surfaces of the rails  102 . Fasteners may extend through the rails  102  into the ends of the leg mount to secure the leg mount  204  to the rails. The width of the leg mount  204  is selected to accommodate, in certain examples, the width of a board member. The leg mount  204  is provided with a pivot mount for allowing the legs  104  to pivot in a longitudinal direction. In other words, the legs  104  are configured to collapse towards each other, and then pivot into a cavity formed by the rails  102 . 
     In certain embodiments, the pivoting mount points  1402  of the legs on the leg mount  204  are spaced apart a distance  1404  of between about 2 and 10 inches. This beneficially provides stability to the work support  100 . Conversely, many common work supports have legs that are attached to the same pivot point which is less stable. 
       FIG.  15    is a perspective view diagram illustrating one example of a saw-horse configuration of the work support  1500  in accordance with examples of the present disclosure. As discussed above, the work support may be configured as a sawhorse with a work surface. The work surface, in certain examples, is a sacrificial board member such as a 2×8. In other examples, the work surface is coupled to the work support  1500 . 
       FIG.  16    is a schematic block diagram illustrating one embodiment of the work support  100  in accordance with examples of the present disclosure. The depicted embodiment illustrates the legs  104  in the folded or storage position, as opposed to the extended or working position described above (see also  FIG.  1   ). The legs  104  pivot into a cavity formed by the rails  102 . The legs  104  may be secured in place by the butterfly handle  312 . 
       FIGS.  17   a - 17   e    are cross-sectional diagrams illustrating rails, according to examples of the subject disclosure. In the depicted examples, the rail  102  described above with reference to  FIGS.  1 - 16    may be replaced with many variations of cross-sectional profiles. In each example, however, the interior side  1702  of each rail includes a t-track  1704 . Exterior surfaces may be planar, or substantially planar (e.g.,  FIGS.  17   a ,  17   b ,  17   c , and  17   e   ) or curvilinear (e.g.,  FIG.  17   d   ). The exterior surfaces may include one or more t-tracks  1704  which are useful for attaching accessories, as described above. 
     In the above description, certain terms may be used such as “up,” “down,” “upper,” “lower,” “horizontal,” “vertical,” “left,” “right,” “over,” “under” and the like. These terms are used, where applicable, to provide some clarity of description when dealing with relative relationships. But, these terms are not intended to imply absolute relationships, positions, and/or orientations. For example, with respect to an object, an “upper” surface can become a “lower” surface simply by turning the object over. Nevertheless, it is still the same object. Further, the terms “including,” “comprising,” “having,” and variations thereof mean “including but not limited to” unless expressly specified otherwise. An enumerated listing of items does not imply that any or all of the items are mutually exclusive and/or mutually inclusive, unless expressly specified otherwise. The terms “a,” “an,” and “the” also refer to “one or more” unless expressly specified otherwise. Further, the term “plurality” can be defined as “at least two.” 
     Additionally, instances in this specification where one element is “coupled” to another element can include direct and indirect coupling. Direct coupling can be defined as one element coupled to and in some contact with another element. Indirect coupling can be defined as coupling between two elements not in direct contact with each other, but having one or more additional elements between the coupled elements. Further, as used herein, securing one element to another element can include direct securing and indirect securing. Additionally, as used herein, “adjacent” does not necessarily denote contact. For example, one element can be adjacent another element without being in contact with that element. 
     As used herein, the phrase “at least one of”, when used with a list of items, means different combinations of one or more of the listed items may be used and only one of the items in the list may be needed. The item may be a particular object, thing, or category. In other words, “at least one of” means any combination of items or number of items may be used from the list, but not all of the items in the list may be required. For example, “at least one of item A, item B, and item C” may mean item A; item A and item B; item B; item A, item B, and item C; or item B and item C. In some cases, “at least one of item A, item B, and item C” may mean, for example, without limitation, two of item A, one of item B, and ten of item C; four of item B and seven of item C; or some other suitable combination. 
     Unless otherwise indicated, the terms “first,” “second,” etc. are used herein merely as labels, and are not intended to impose ordinal, positional, or hierarchical requirements on the items to which these terms refer. Moreover, reference to, e.g., a “second” item does not require or preclude the existence of, e.g., a “first” or lower-numbered item, and/or, e.g., a “third” or higher-numbered item. 
     As used herein, a system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is indeed capable of performing the specified function without any alteration, rather than merely having potential to perform the specified function after further modification. In other words, the system, apparatus, structure, article, element, component, or hardware “configured to” perform a specified function is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the specified function. As used herein, “configured to” denotes existing characteristics of a system, apparatus, structure, article, element, component, or hardware which enable the system, apparatus, structure, article, element, component, or hardware to perform the specified function without further modification. For purposes of this disclosure, a system, apparatus, structure, article, element, component, or hardware described as being “configured to” perform a particular function may additionally or alternatively be described as being “adapted to” and/or as being “operative to” perform that function. 
     The schematic flow chart diagrams included herein are generally set forth as logical flow chart diagrams. As such, the depicted order and labeled steps are indicative of one example of the presented method. Other steps and methods may be conceived that are equivalent in function, logic, or effect to one or more steps, or portions thereof, of the illustrated method. Additionally, the format and symbols employed are provided to explain the logical steps of the method and are understood not to limit the scope of the method. Although various arrow types and line types may be employed in the flow chart diagrams, they are understood not to limit the scope of the corresponding method. Indeed, some arrows or other connectors may be used to indicate only the logical flow of the method. For instance, an arrow may indicate a waiting or monitoring period of unspecified duration between enumerated steps of the depicted method. Additionally, the order in which a particular method occurs may or may not strictly adhere to the order of the corresponding steps shown. 
     The present subject matter may be embodied in other specific forms without departing from its spirit or essential characteristics. The described examples are to be considered in all respects only as illustrative and not restrictive. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.