Patent Publication Number: US-2020290138-A1

Title: Track saw system

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims priority to co-pending U.S. Provisional Patent Application No. 62/942,373 filed on Dec. 2, 2019 and co-pending U.S. Provisional Patent Application No. 62/818,405 filed on Mar. 14, 2019, the entire contents of both of which are incorporated herein by reference. 
    
    
     FIELD OF THE DISCLOSURE 
     The present disclosure relates to power tools, and more particularly to track saw systems. 
     BACKGROUND OF THE DISCLOSURE 
     Track saws are traditionally used to make relatively long, straight cuts in sheets of work material. Generally, a saw is translated along a track that is aligned as desired on the sheet of work material. Tracks can be oriented at a desired miter angle within the plane of the sheet of work material relative to an edge of the sheet. Also, with traditional track saw systems, a user must remove the track from the sheet of work material after performing a miter cut, therefore requiring the user to set up the track at the desired miter angle again if it is desired to cut another sheet of work material at the same miter angle. 
     SUMMARY OF THE DISCLOSURE 
     The present disclosure provides, in one aspect, a track saw system configured to make a straight cut in a work piece supported upon a stand. The track saw system includes a base configured for attachment to the stand, the base having an edge against which the work piece is engageable, a track pivotably coupled to the base, a first hinge pivotably coupling the track to the base about a first pivot axis to permit pivoting movement of the track relative to the base in a direction extending away from the base, and a second hinge pivotably coupling the track to the base about a second pivot axis transverse to the first pivot axis to permit pivoting movement of the track relative to the base to adjust a miter angle between the track and the edge. 
     The present disclosure provides, in another independent aspect, a track saw system configured to make a straight cut in a work piece supported upon a stand. The track saw system includes a base configured for attachment to the stand, the base having an edge against which the work piece is engageable, a track having a first portion coupled to the base and a second portion pivotably coupled to the base, and a hinge connecting the first and second portions of the track to permit pivoting movement of the second portion of the track relative to the base in a direction extending away from the base. 
     Other features and aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the track saw system in accordance with an embodiment of the present disclosure. 
         FIG. 2  is an alternate perspective view of the track saw system of  FIG. 1 . 
         FIGS. 2A-2D  are top views of indicating assemblies of the track saw system of  FIG. 1 . 
         FIG. 3  is a side view of the track saw system of  FIG. 1 , illustrating a track in a raised position. 
         FIG. 4  is a side view of a track saw system in accordance with another embodiment of the present disclosure, illustrating a track in a raised position. 
     
    
    
     Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     DETAILED DESCRIPTION 
       FIG. 1  illustrates a track saw system  100  according to an embodiment of the disclosure. The track saw system  100  includes a track saw  104 , a track  108 , an angle finding device or miter gauge  112 , and a pivot hinge assembly  114  configured to lift the track  108  from a work piece before and/or after a cutting operation is performed. The track saw  104  includes a shoe  116  having grooves  118  that correspond to parallel rails  120  of the track  108 . The grooves  118  in the shoe  116  receive the exterior rails  120  of the track  108 , and enable the saw  104  to slide along the track  108  such that a blade  124  of the track saw  104  translates parallel to the track  108  along a cut line coinciding with one edge  128  of the track  108 . 
     The track saw system  100  is supported by a stand  200  through a base  300 . The stand  200  may be considered a miter saw stand by one of ordinary skill in the art at the time of the invention. The stand  200  is capable of supporting large and heavy work pieces W thereon at a height disposed from the ground which is comfortable for a user to access the base  300  and the track saw system  100 . The base  300  includes at least one arm  304  having an edge locator  308  at an end thereof. A user may slidably translate the arm  304  with the base such that the location of the edge locator  308  translates relative to the base  300 . This allows the base  300  to accommodate varying sizes of work pieces W. In a cutting position of the work piece W on the base  300 , an edge E of the work piece W abuts (i.e., engages) the edge locator  308 . The base  300  also includes a table  312  having a plurality of holes  316  in which stand-offs or posts  320  may be received in a number of different positions throughout the table  312 . The posts  320  support a work piece W, and prevent sagging and/or bowing of the work piece W during the cutting operation. The posts  320  provide a clearance between the base  300  and a bottom surface of the work piece W such that the blade  124  can cut through the work piece W without cutting the table  312 . The posts  320  can be shifted from one hole to another such that the posts  320  are not aligned with the cut line coinciding with the edge  128  of the track  108  in any adjusted miter angle of the track  108 . 
     With reference to  FIG. 2 , the miter gauge  112  includes a bracket  132  that is attachable to the track  108  (e.g., the lower surface and/or a receptacle defined in the track  108 ). The bracket  132  can be vertically displaced to adjust a distance between the track  108  and the table  308 . The bracket  132  is attachable to an extension tube  136  that extends generally orthogonal from the track  108 . The extension tube  136  is received and slidable within a cross-fitting  140 , which in turn is slidably supported upon a lateral extension tube  144 . A miter clamp  148  includes a split collar  152  encircling the extension tube  136  and an over-center cam lever  156  to selectively apply a clamping force to the collar  152 , and thus the extension tube  136 , to lock the extension tube  136  and the track  108  at a fixed height with respect to the table  312 . This adjustment permits various thicknesses of work pieces W to fit between the track  108  and the table  312 . The miter clamp  148  may be positioned, above, below, or otherwise adjacent the cross-fitting  140  to hold the cross-fitting  140  in place when the miter clamp  148  is engaged. The miter clamp  148  also holds the cross-fitting  140  in place with the track  108  at the desired miter angle defined between the edge  128  of the track  108  and the edge E of the work piece W. In one embodiment of the system  100 , the bracket  132  is also detachable from the track  108 , permitting the user to remove the miter gauge  112  from the track  108  for storage or transport. In another embodiment of the system  100 , the bracket  132  may be permanently affixed to the track  108  (e.g., by integrally forming the bracket  132  and track  108 , or by fastening the bracket  132  to the track  108 ). 
     As illustrated in  FIG. 2 , the miter gauge  112  is capable of being rotated about an axis  160  defined by the extension tube  136  to a desired miter angle defined between the edge  128  of the track  108  and the edge E of the work piece W (and thus a plane defined by the aligned edge locators  308 ). The bracket  132  includes a handle portion  164 , which a user can grasp to move and reposition the bracket  132 . The miter gauge  112  further includes a pointer (not shown) and a scale (not shown) to indicate the particular miter angle to which the miter gauge  112  is set. Detents (not shown) may be provided to produce an audible and/or tactile indication to a user that the miter gauge  112  is adjusted to a predefined common miter angle (e.g., 45 degrees, 22.5 degrees, etc.). In one embodiment, detents engage the extension tube  136 , and stops engage the cross-fitting  140 . In other embodiments, detents may be attached to other components of the miter gauge  112  such as, without limitation, the collar  152 , the handle  164 , or the bracket  132 . In other embodiments, detents may be provided as a part of the stand  200  or the base  300  to provide predefined common miter angle stops to the miter gauge  112 . In further other embodiments, the detents may be replaced with another structure for stopping the track  108  at a common miter angle relative to the edge E. This other structure may be, without limitation, a biased pin engaging a through hole in a plate, a discretely telescoping tube engaging the track  108 , or a hinge permitting rotation through discrete ranges of motion with stops at common miter angles. Optionally, the miter gauge  112  may include an electronic display to provide a user indication of the angle of the track  108  relative to the edge E. This electronic display may numerically, diagrammatically, or otherwise allow a user to view the angle of the track  108 . 
       FIGS. 2A-2D  illustrate miter gauge indicating assemblies  412 ,  512 ,  612 ,  712 . The miter gauge indicating assemblies  412 ,  512 ,  612 ,  712  each include a pointer  413 ,  513 ,  613 ,  713  and a scale  415 ,  515 ,  615 ,  715  to indicate the particular miter angle to which the respective miter gauge  112  is set. The illustrated and described miter gauge indicating assemblies  412 ,  512 ,  612 ,  712  are non-limiting examples of indicating assemblies which may be combined with the miter gauge  112  to indicate the position of the track  108  relative to the edge E. 
     In a first indicating assembly  412  shown in  FIG. 2A , the scale  415  is beneath the track  108  and is configured to abut the edge E of the work piece W. The pointer  413  is applied to the track  108  in a post-process operation such as, without limitation, painting or etching of the pointer  413  on the track. 
     In a second indicating assembly  512  shown in  FIG. 2B , the scale  515  is beneath the track  108 , and is configured to abut the edge E of the work piece W. The pointer  513  may be adjacent a window  517  or other aperture within the track  108 . The window  517  may be cut or otherwise removed from the track  108  in a post-process operation of the track  108 . The window  517  provides a user a line of sight through the track  108  to the scale  515  beneath the track  108 . 
     In a third indicating assembly  612  shown in  FIG. 2C , the scale  615  is provided on the top surface of the track  108 . The scale  615  is applied to the track  108  in a post-process operation such as, without limitation, painting or etching of the scale  615  on the track  108 . In this embodiment, the pointer  613  is provided by aligning the edge E of the work piece W with the desired angle shown on the scale  615 . In other words, the edge E acts as the pointer  613  in the third indicating assembly  612 . 
     In a fourth indicating assembly  712  shown in  FIG. 2D , the scale  715  can be attached to the track  108  through a linkage mechanism  717  which is connected to the track  108 . The scale  715  abuts the edge E of the work piece W in a position not vertically aligned with the track  108 . This vertical misalignment of the scale  715  from the track  108  allows a user a line of sight to the scale  715  without interference from the track  108 . The pointer  713  is provided with the scale  715 , and is permitted to rotate with the linkage mechanism  717  as the track  108  is rotated to a mitered position relative to the edge E. 
     During operation, the user can adjust the miter angle of the track  108  relative to the edge E of the work piece W. With the miter gauge  112  attached to the track  108 , the user aligns the edge locator  308  against the edge E of a work piece W. The user releases the miter clamp  148  and rotates the combination of the bracket  132 , the extension tube  136 , the handle  164 , and the track  108  relative to the edge locator  308  until a desired miter angle is achieved. During this operation, the cross-fitting  140  can be slidable along the extension tube  144  or locked to the extension tube  144 , as described in further detail below. If the desired miter angle coincides with a predefined common miter angle, the detent or stop will provide an audible and/or tactile indication to the user upon reaching the desired miter angle. At this point, the miter clamp  148  is tightened to maintain the desired angle while the saw  104  is slid across the track  108  to perform a cutting operation. The miter clamp  148  allows for vertical translation of the track  108  relative to the table  308  and radial adjustment (i.e., miter angle adjustment) of the track  108  relative to the edge E of the work piece W. 
     The pivot hinge assembly  114  of the track saw system  100  is capable of lifting the track  108  away from the table  312  and translating the track  108  laterally. The pivot hinge assembly  114  includes the lateral extension tube  144  and a hinge clamp  168 . The hinge clamp  168  may include a split collar and an over-center cam lever similar to the miter clamp  148 . Alternatively, the hinge clamp  168  may include a spring-biased detent. The illustrated hinge clamp  168  includes a bolt  170  extending from one side of the lateral extension tube  144 , through a hole  174  the lateral extension tube  144 , and engaging a nut (not shown) on the opposite side of the lateral extension tube  144 . The extension tube  144  may include multiple holes  174  for selectively positioning the cross-fitting  140  at various discrete positions along the extension tube  144 . Hinge clamps  168  and bolts  170  may be positioned on one or both sides along the axis  180  when compared to the cross-fitting  140 . The bolt  170  and nut selectively apply a clamping force to the hinge clamp  168  onto the lateral extension tube  144 . Other means of fastening the cross-fitting  140  along the extension tube  144  are possible. The hinge clamp  168  may be positioned to the left of, to the right of, or otherwise adjacent the cross-fitting  140  to hold the cross-fitting  140  in place when the hinge clamp  168  is engaged. The cross-fitting  140  is both translatable and rotatable relative to the lateral extension tube  144 . The lateral position of the cross-fitting  140  along the lateral extension tube  144  is selectively fixed to the lateral extension tube  144 , and thus the remainder of the base  300 , through the hinge clamp  168 . As shown in  FIG. 3 , the hinge clamp  168  is also capable of securing the cross-fitting  140  at a given rotational position about an axis  180  defined by the lateral extension tube  144  such that the track  108  may be angled relative to a work piece W at a desired hinge angle  184 . The axis  180  of the lateral extension tube  144  is orthogonal to the axis  160  of the extension tube  136 , and the two axes  160 ,  180  do not intersect each other. In the illustrated embodiment, the axis  160  is closer to the handle portion  164  than the axis  180 . The cross-fitting  140  is capable of independent adjustment rotationally about and translational along both the axis  160  and the axis  180 . The hinge clamp  168  can also be loosened relative to the lateral extension tube  144  to permit translation of the cross-fitting  140  along the lateral extension tube  144 . When the hinge clamp  168  is tightened, the position of the cross-fitting  140  along the lateral extension tube  144  is fixed. In some embodiments, the a combination of the cross-fitting  140  and the extension tube  144  defines a first hinge of the track saw system  100  that pivotably couples the track  108  to the base  300  about the pivot axis  180  to permit pivoting movement of the track  108  relative to the base  300  in a direction extending away from the base  300 . And, in some embodiments, a combination of the cross-fitting  140  and the extension tube  136  defines a second hinge pivotably coupling the track  108  to the base  300  about another pivot axis  160  transverse to the pivot axis  180  to permit pivoting movement of the track  108  relative to the base  300  to adjust a miter angle between the track  108  and the edge E of the work piece W. 
     In operation of the pivot hinge assembly  114 , the track  108  may be locked in a raised position as shown in  FIG. 3 . A user places a work piece Won the table  312  with the edge E abutting the edge locator  308 . The user unlocks the hinge clamp  168  and rotates the track  108  downwards (i.e., opposite the arrow in  FIG. 3 ) such that it rests upon the work piece W. A lateral position of the track  108  can be adjusted by sliding the cross-fitting  140  along the lateral extension tube  144 . The user can then release the miter clamp  148  of the miter gauge  112  to set a vertical position of the track  108  and the miter angle of the track  108 , if a change in track height and/or miter angle is desired. With the track  108  in position, the saw  104  can be translated along the track  108  to cut the work piece W. After the cutting operation, the user can unlock the hinge clamp  168 , pivot the track upward and away from the table  308  (i.e., away from the lowered position in the direction of the arrow in  FIG. 3 ), and lock the track  108  in the raised position without disturbing the vertical position and miter angle of the miter gauge  112 . The user can replace the cut work piece from the table  308  with another work piece W, and repeat the process of operating the pivot hinge assembly  114  with the new work piece W positioned on the table  312 . Optionally, with the miter gauge  112  and the pivot hinge assembly  114 , the user can adjust the lateral position, vertical position, and miter angle of the track  108  with the new work piece W or when making an additional cut in the first work piece. 
     In another embodiment of a track saw system  1000  shown in  FIG. 4 , with like features being labeled with like reference numerals, a hinge  1014  is positioned between opposite ends of the track  1008  to permit a first portion  1008   a  of the track  1008  to be inclined relative to a stationary or second portion  1008   b  of the track  1008  (and the attached base  1300 ). In this embodiment, the hinge  1014  permits a user to pivot the movable portion  1008   a  of the track  1008  relative to the stationary portion  1008   b  of the track  1008  in a direction away from the base  1300  (i.e., along the arrow in  FIG. 4 ). In this embodiment, the stationary portion  1008   b  of the track  1008  can support the saw  1004  when the movable portion  1008   a  of the track  1008  is inclined relative to the stationary portion  1008   b  of the track  1008  to, for example, exchange a work piece to be cut. It is envisioned that a locking mechanism  1010  between the movable portion  1008   a  and stationary portion  1008   b  of the track  1008  is capable of maintaining the movable portion  1008   a  in an inclined position (i.e., at a given hinge angle  1084 ) while the work pieces are exchanged. The stationary portion  1008   b  of the track  1008  is capable of miter angle adjustment and vertical adjustment using a miter gauge  1012  like that disclosed in connection with the track saw system  100 . 
     Various features of the invention are set forth in the following claims.