Patent Abstract:
A laminate flooring saw system which can be used for both rip cuts and miter cuts in one embodiment includes a first power switch proximate the saw and movable with the saw along a support arm;
   a second power switch that is not movable with the saw along the support arm;   and   a third switch movable between a first position wherein application of energy to the saw is dependent upon the position of the second power switch and independent of the position of the first power switch and a second position wherein application of energy to the saw is dependent upon the position of both the first power switch and the second power switch.

Full Description:
This application is a divisional application of application Ser. No. 12/199,604, filed on Aug. 27, 2008, and which will issue on May 29, 2012 as U.S. Pat. No. 8,186,257, the disclosure of such application which is totally incorporated by reference herein in its entirety. 
    
    
     FIELD OF THE INVENTION 
     This invention relates to the field of devices used to support and shape work-pieces and particularly to a device for supporting and cutting work-pieces. 
     BACKGROUND 
     Laminate flooring is a popular flooring product due to its ease of installment as well as its performance. Additionally, the various designs which are available for laminate flooring enhance its popularity with consumers. The designs include wood-grain patterns, slate, marble, mosaic, and granite. Additionally, a number of specialized products have been designed to ease installation of laminate flooring. Such products include transition strips, end caps, stair nosings, moldings and baseboards. 
     When laminates were first introduced, there was only one method of installation. The laminates were produced in a “tongue and groove” design. When installing the laminate, the tongue and grooves were glued together, then clamped and left to dry. Manufacturers have since developed flooring that requires no glue at all. 
     Accordingly, installation of laminate flooring has been significantly simplified. One difficult aspect of installation that remains, however, is cutting the laminate flooring to fit within a particular area. Most laminates are provided in planks that are 7-8 inches wide and about 4 foot long. Depending upon the width of a room, the final course of planks may need to be ripped to the appropriate width. Moreover, the lengths of the planks at opposing walls need to be trimmed. Additionally, miter cuts may be required to contour the planks to fit the contours of a particular room. 
     Traditionally, a number of different types of saws have been used to make the necessary miter and rip cuts in laminate floors. Such saws include table saws, hand saws, jig saws and circular saws. Each of these types of saws provides some advantages. A table saw gives very precise cuts and can be used to rip cut a work-piece. Additionally, table saws can be configured to provide angled cuts by angling the work-piece. Table saws, even the “portable” table saws, however, are large and heavy. Thus, an installer must either accept the difficulty in transporting the table saw near the area where the laminate is to be installed or carry each piece of laminate back and forth from the work area to the saw location. Additionally, many homeowners attempt to install a laminate floor on their own. In the event the homeowner does not own a table saw, a different approach is needed. 
     Hand saws are, in stark contrast to table saws, extremely mobile. Hand saws are also, however, labor intensive. Thus, while handsaws may reasonably be used to make cuts of a few feet, the large number of planks that may need to be cut for a particular installation presents a daunting challenge to those using handsaws. Moreover, handsaws are generally not as accurate as table saws. 
     Jig saws and circular saws are generally much more “portable” than table saws and greatly facilitate making a large number of cuts. Depending upon the particular jigs available to an installer, however, these saws still do not provide the accuracy achievable with a table saw. Thus, while professional installers may become very skilled with using a jig saw or circular saw, other users may generate an undesired amount of scrap as a result of erroneous cuts. 
     What is needed is a system which can be used to rip cut a work piece and to miter cut the work piece. What is further needed is a system which is portable so that it can be located at a work site. A further need is for a system that can provide the required portability while providing accurate cuts. 
     SUMMARY 
     In accordance with one embodiment of the present invention, there is provided a laminate flooring saw system which can be used for both rip cuts and miter cuts. In one embodiment the flooring saw system includes a fence, a base including a first locking member configured to cooperate with the fence to lock the fence along a first fence axis, a second locking member configured to cooperate with the fence to lock the fence along a second fence axis, the second fence axis perpendicular to the first fence axis and a support arm positioned above the base for supporting a power tool. 
     In accordance with another embodiment of the present invention, there is provided a portable saw system including a base, a movable support arm, a saw movable along the support arm, a first power switch proximate the saw and movable with the saw along the support arm, a second power switch that is not movable with the saw along the support arm and a third switch movable between a first position wherein application of energy to the saw is dependent upon the position of the first power switch and independent of the position of the second power switch and a second position wherein application of energy to the saw is dependent upon the position of both the first power switch and the second power switch. 
     In accordance with a further embodiment, a portable saw system includes a base with an articulation surface, an articulating platform configured to articulate on the articulation surface and to define a cutting axis and a pivot defining a pivot axis and pivotably connecting the articulating platform with the base, the pivot positioned such that the cutting axis intersects the pivot axis. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts a perspective view of a laminate flooring saw system in accordance with principles of the present invention; 
         FIG. 2  depicts an exploded perspective view of the laminate flooring saw system of  FIG. 1 ; 
         FIG. 3  depicts the base of the laminate flooring saw system of  FIG. 1  with the fence and articulating support structure removed; 
         FIG. 4  depicts a perspective view of the fence of the laminate flooring saw system of  FIG. 1 ; 
         FIG. 5  depicts a top plan view of the articulating support structure of the laminate flooring saw system of  FIG. 1 ; 
         FIG. 6  depicts a side plan view of the articulating support structure of the laminate flooring saw system of  FIG. 1  with a plunger in an extended position; 
         FIG. 7  depicts a side perspective view of the base pillar of the articulating support structure of the laminate flooring saw system of  FIG. 1  showing a coiled power cord receptacle; 
         FIG. 8  depicts a side perspective view of the base pillar of the articulating support structure of the laminate flooring saw system of  FIG. 1  showing a toggle switch in accordance with principles of the invention; 
         FIG. 9  depicts a side perspective view of the locking pillar of the articulating support structure of the laminate flooring saw system of  FIG. 1  showing a rip lock button and a miter lock arm; 
         FIG. 10  depicts a side perspective view of the locking pillar of the articulating support structure of the laminate flooring saw system of  FIG. 1  showing a rip lock release button and a female A/B switch member; 
         FIGS. 11-13  depict various perspective views of the power tool of the laminate flooring saw system of  FIG. 1 ; 
         FIG. 14  shows a schematic diagram of the electrical control circuit used to alternatively enable use of a momentary power switch for making miter cuts and a toggle switch for making rip cuts in accordance with principles of the invention; 
         FIG. 15  depicts a top perspective view of the laminate flooring saw system of  FIG. 1  with the fence removed; 
         FIG. 16  depicts a top perspective view of the laminate flooring saw system of  FIG. 1  with the fence and the articulating support structure positioned for making a rip cut in accordance with principles of the invention; and 
         FIG. 17  depicts a top perspective view of the laminate flooring saw system of  FIG. 1  with the fence positioned for making a miter cut and the articulating support structure positioned to make a ninety degree miter cut in accordance with principles of the invention. 
     
    
    
     DESCRIPTION 
     For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains. 
       FIGS. 1 and 2  show a portable laminate flooring saw system  100 . The system  100  includes a base  102 , an articulating support structure  104  and a fence  106 . A power tool  108  is supported by the support structure  104 . The base  102  includes an upper table portion  110  and a sunken articulation surface  112 . Two openings  114  and  116  extend through the base  102  to provide handholds. With reference to  FIG. 3 , a locking member  118  has an axis  120  that is substantially parallel to a rip edge  122 . A locking member  124  has an axis  126  that is substantially parallel to a miter edge  128 . 
     The sunken articulation surface  112  opens to the miter edge  128 . A wall  130  on one side of the articulation surface  112  extends inwardly from the miter edge  128  and defines a recessed area  132 . The articulation surface  112  terminates at a wall portion  134  at a curved edge portion  136  which includes a graduated angle indicator  138 . A wall  140  extends from the sunken articulation surface  112  to the upper table portion  110 . The wall  140  includes an arced portion  142 . A number of evacuation ports  144 , a pivot opening  146  and a guide slot  148  extend through the base  102  from the sunken articulation surface  112 . A lock bore  150 , which in this embodiment also extends through the base  102 , is located proximate to the curved edge portion  136 . 
     The fence  106  is shown in  FIG. 4 . The fence  106  includes a main body  152  and a shaft  154 . The shaft  154  includes two dog holes  156  and  158 . The dog holes  156  and  158  may be used to attach accessories to the portable saw system  100  such as hold-down devices. One side  167  of the shaft  154  opens to a blade cutout  160  while the other side  169  does not incorporate a cutout. A locking mechanism  162  includes a movable dog  164  and a fixed dog  166 . A handle  168  extends outwardly from the body  152  and is operably connected to the movable dog  164 . 
     The articulating support structure  104  is shown in  FIGS. 5 and 6  with the power tool  108  removed. The articulating support structure  104  includes an articulating base  170  with an extension  172 , a support arm base portion  174  and a pivot base portion  176 . A blade slot  178  extends through the articulating base  170  and is aligned with a pivot  180 . A base pillar  182  is located on the support arm base portion  174  and a locking pillar  184  is located on the extension  172 . A cord support arm  186  and two circular support arms  188  and  190  extend between the base pillar  182  and the locking pillar  184 . A locking boss  192  with an enlarged head  194  is located beneath the locking pillar  184  and a movable plunger  196  is shown extending from the locking pillar  184  and through the articulating base  170 . 
     Referring to  FIGS. 7 and 8 , the base pillar  182  includes a power cord receptacle  200  and a toggle switch  202 . The power cord receptacle  200  is sized to store a coiled power cord  204  which is coiled about the cord support arm  186 . The cord support arm  186  extends outwardly from the receptacle  200 . An external power cord  206  is received into the base pillar  182 . 
     The locking pillar  184  is shown in  FIGS. 9 and 10 . A rip lock button  210  is located on the top of the locking pillar  184  and a miter lock arm  212  is located on the outer side of the locking pillar  184 . The locking pillar  184  further includes a rip lock release button  214  and a keyed female A/B switch member  216 . 
       FIGS. 11 ,  12  and  13  show the power tool  108  removed from the cord support arm  186  and the two circular support arms  188  and  190 . The power tool  108  in this embodiment is a circular saw including a motor housing  220 , a gear box  222 , a blade guard  224  and a handle housing  226 . The handle housing  226  includes three bores  228 ,  230  and  232  sized to receive the cord support arm  186  and the two circular support arms  188  and  190 , respectively. A momentary power switch  234  and a lockout switch  236  extend out of the handle housing  226  and a grip  238  is located at the rear  240  of the handle housing  226 . A keyed male A/B switch  242  is located below the bore  232  at the rear  240  of the housing  226 . The coiled power cord  204  is received by a power port  244  located at the front portion  246  of the handle housing  226 . 
     The blade guard  224  is configured to receive a blade (not shown) operably connected to the power tool  108 . A connection member  250  located at the forward portion of the blade guard  224  is provided for attachment of a hold-down bracket (not shown) and two kick-back pawls  252  and  254  are located on a positionable riving knife  256  located at the rear of the blade guard  224  below a riving knife locking knob  258 . An extension  260  is pivotably attached to the lower portion of the blade guard  224 . 
     A schematic of the electrical system  270  of the portable saw system  100  is shown in  FIG. 14 . The electrical system  270  includes the toggle switch  202  which extends from the base pillar  182 , the momentary switch  234  which extends from the handle housing  226  and an A/B switch  272  which, in this embodiment, is located in the handle housing  226 . The toggle switch  202  is positionable to apply energy to either a terminal  274  or a terminal  276 . 
     The terminal  274  is connected through a lead  278  to the momentary switch  234 . The momentary switch  234  is biased to contact a terminal  280  which is electrically isolated. By application of pressure, the momentary switch  234  can be positioned to contact a terminal  282  which is connected by a lead  284  to a terminal  286  associated with the A/B switch  272 . The terminal  276  associated with the toggle switch  202  is connected by a lead  290  to a second terminal  292  associated with the A/B switch  272 . The A/B switch  272 , which is biased to contact the terminal  286 , is connected to a motor  294  in the motor housing  220  by a lead  296 . 
     The portable saw system  100  may be operated in accordance with the following examples. In one example, operation of the portable saw system  100  begins with the fence  106  removed as shown in  FIG. 15 . With reference to  FIGS. 1-6 , the articulating base  170  of the articulating support structure  104  is positioned on the sunken articulation surface  112 . The pivot  180  extends through the pivot opening  146  and the locking boss  192  extends through the guide slot  148 . The miter lock arm  212  is positioned against the locking pillar  184 , thereby locking the articulating support structure  104  on the base  102 . While a number of variations are possible, the miter lock arm  212  in this embodiment pulls the enlarged head  194  of the locking boss  192  (see  FIG. 6 ) upwardly against the base  102  as the miter lock arm  212  is pivoted toward the locking pillar  184 . 
     With further reference to  FIGS. 11-13 , the power tool  108  is slidably mounted on the articulating support structure. Specifically, the circular arm  188  slidably extends through the bore  230 , the circular arm  190  slidably extends through the bore  232  and the power cord support arm  186  slidably extends through the bore  238 . When so positioned, the saw blade (not shown) attached to the power tool  108  extends into the blade slot  178  while the extension  260  is pivotably biased against the articulating base  170 . Thus, no portion of the saw blade (not shown) is exposed to a user. 
     With the portable saw system  100  in this configuration, the operator determines the type of cut that is needed on a work-piece. In the event that the operator desires to perform a rip cut on a work-piece, the fence  106  is positioned on the base  102  with the locking mechanism  162  positioned over the locking member  124  and the handle  168  in a raised position as shown in  FIG. 4 . Once the fence  106  is positioned along the locking member  124  at a location corresponding the to desired width of the work-piece, the handle  168  is moved in a downwardly direction from the position shown in  FIG. 4  to the position shown in  FIG. 16 , thereby moving the movable dog  164  against the locking member  124  so as to clamp the locking member  124  between the movable dog  164  and the fixed dog  166 . Thus, the side  169  of the shaft  154  defines a guide axis perpendicular to the axis  126  associated with the locking member  124  (see  FIG. 3 ). In alternative embodiments, a handle may move a member located between two dogs to clamp the fence. 
     Next, the articulating support structure  104  is unlocked from the base  102  by movement of the miter lock arm  212  in the direction of the arrow  300  in  FIG. 16 . The articulating support structure  104  is then pivoted about the pivot axis  302  defined by the pivot  180  in the direction of the arrow  304  until the articulating support structure  104  abuts the wall  140 . The articulating support structure  104  is then locked into position by movement of the miter lock arm  212  in the direction opposite the arrow  300  in  FIG. 16 , thereby pulling the enlarged head  194  against the base  102 . 
     Positioning the articulating support structure  104  against the wall  140  places the circular arms  188  and  190  in a position parallel to the shaft  154 . Additionally, the plunger  196  is aligned with the locking bore  150 . The plunger  196  is then extended into the locking bore  150  by depressing the spring loaded rip lock button  210 . As the plunger  196  extends into the locking bore  150 , the rip lock release button  214  automatically engages the plunger  196  locking the plunger  196  within the locking bore  150 . 
     Depression of the rip lock button  210  further causes the female A/B switch member  216  to be configured to accept the male A/B switch member  242 . The power tool  108  may then be slid along the circular arms  188  and  190  until the male A/B switch member  242  enters the female A/B switch member  216 . To ensure the power tool  108  is not accidentally energized during this movement, the lockout switch  236  may be depressed. Depression of the lockout switch  236  locks the momentary power switch  234  into contact with the electrically isolated terminal  280  (see  FIG. 14 ). 
     Continuing with  FIG. 14 , as the male A/B switch member  242  enters the female A/B switch member  216 , the A/B switch  272 , which is biased toward the terminal  286 , is forced away from the terminal  286  and into contact with the terminal  292 . Accordingly, the motor  294  may be energized by movement of the toggle switch  202  into contact with the terminal  276 . 
     Returning to  FIG. 16 , prior to energizing the portable tool  108 , the riving knife  256  and the kick-back pawls  252  and  254  are positioned and secured using the riving knife locking knob  258 . The portable saw system  100  may then be energized by positioning the toggle switch  202  into contact with the terminal  276  and a work-piece fed onto the upper table portion  110  along the fence  104  in the direction of the arrow  306 . As the work-piece engages the extension  260 , the extension  260  is pivoted upwardly away from the articulating base  170  exposing the work-piece to the saw blade (not shown). As the work-piece passes by the saw blade (not shown), the riving knife  256  spreads the cut portions of the work-piece to prevent binding of the saw blade (not shown) by the work-piece. 
     Additionally, the work-piece is positioned underneath the kick-back pawls  252  and  254  as the work-piece passes the saw blade. Accordingly, in the event that the work-piece is forced away from the articulating base  170 , the work-piece would contact the kick-back pawls  252  and  254 . This would generate a torque on the power tool  108 . The power tool  108 , however, is prevented from rotation away from the articulating base  170  by the spacing of the circular arms  188  and  190 . Accordingly kick-back of the work-piece is prevented as is undesired movement of the power tool  108  away from the articulating base  170 . 
     To switch from rip cutting mode to a miter cutting mode after the saw is de-energized, the fence  106  is removed by moving the handle  168  in an upwardly direction from the position shown in  FIG. 16  to the position shown in  FIG. 4 . This moves the movable dog  164  away from the locking member  124 , allowing the fence  106  to be lifted off of the base  102 . 
     Next, the fence  106  is positioned on the base  102  with the locking mechanism  162  positioned over the locking member  118 . Once the fence  106  is positioned on the locking member  118 , the handle  168  is moved in a downwardly direction from the position shown in  FIG. 4  to the position shown in  FIG. 17  thereby moving the movable dog  164  against the locking member  118  so as to clamp the locking member  118  between the movable dog  164  and the fixed dog  166 . Thus, the side  167  of the shaft  154  defines a guide axis perpendicular to the axis  120  associated with the locking member  118  (see  FIG. 3 ). 
     Next, the articulating support structure  104  is unlocked from the base  102  by sliding the power tool  108  along the circular arms  188  and  190  away from the locking pillar  184  until the male A/B switch member  242  exits the female A/B switch member  216 . To ensure the power tool  108  is not accidentally energized during this movement, the lockout switch  236  may be depressed. Depression of the lockout switch  236  locks the momentary power switch  234  into contact with the electrically isolated terminal  280  (see  FIG. 14 ). 
     Continuing with  FIG. 14 , as the male A/B switch member  242  exits the female A/B switch member  216 , pressure from the female A/B switch member  216  is removed from the A/B switch  272 . Thus, because the A/B switch  272  is biased toward the terminal  286 , the A/B switch  272  is forced away from the terminal  292  and into contact with the terminal  286 . Accordingly, the motor  294  may only be energized by movement of the toggle switch  202  into contact with the terminal  274  and movement of the momentary power switch  234  into contact with the terminal  282 . 
     Movement of the male A/B switch member  242  out from the female A/B switch member  216  further allows the plunger  196  to be withdrawn. This is accomplished by depressing the rip lock release button  214  which releases the rip lock button  210 . With the rip lock release button  214  depressed, a spring (not shown) biases the rip lock button  210  in an upwardly direction, thereby withdrawing the plunger  196  from the locking bore  150 . Movement of the plunger  196  out of the locking bore  150  causes the female A/B switch member  216  to be configured to not accept the male A/B switch member  242 . 
     In the event that a ninety degree miter cut is desired, the articulating support structure  104  need not be repositioned. If a different angle is desired, the articulating support structure  104  is positioned to the desired angle by swinging the miter lock arm  212  in the direction of the arrow  300  in  FIG. 16 . This moves the enlarged head  194  away from the base  102 . The articulating support structure  104  is then pivoted about the pivot axis  302  defined by the pivot  180  in the direction of the arrow  306  until the articulating support structure  104  is at the desired angle. The graduated angle indicator  138  may be used to assist in positioning the articulating support structure  104 . 
     In this embodiment, when the articulating support structure  104  is positioned with the extension  172  fully positioned within the recessed portion  132 , a 45 degree miter cut may be executed on a work-piece. Thus, the articulating support structure  104  can be positioned to provide a miter cut at any desired angle between 45 degrees and 90 degrees. Additionally, because the portable saw system  100  is configured to align a saw blade held by the power tool  108  with the blade slot  178 , the cutting axis of the power tool  108  is aligned with the pivot  180  throughout the range of motion of the articulating support structure  104 . 
     Once the articulating support structure  104  is in the desired position, the miter lock arm  212  is pivoted in the direction opposite the arrow  300  in  FIG. 16  thereby pulling the enlarged head  194  against the base  102  to lock articulating support structure  104  at the desired position. 
     Prior to performing a miter cut, the riving knife  256  and the kick-back pawls  252  and  254  are moved away from the articulating base  170  and secured using the riving knife locking knob  258 . Additionally, a hold down clamp may be attached to the blade guard  224  using the connection member  250 . After setting the height of the hold down clamp as desired, a work-piece is positioned on portable saw system  100 . Specifically, the work-piece is positioned against the shaft  154  of the fence  106  and upon the top of the articulating base  170 . Depending upon the particular cut and work-piece, the work-piece may also extend onto the upper table portion  110 . To facilitate placement of a work-piece across both the articulating base  170  and the upper table portion  110 , the height of the articulating base  170  is substantially the same as the height of the wall  140 . 
     The portable saw system  100  may then be energized by positioning the toggle switch  202  into contact with the terminal  274  and depressing the momentary power switch  234  thereby placing the momentary power switch  234  into contact with the terminal  282 . With the power tool  108  energized, the operator slides the power tool  108  along the circular arms  188  and  190  toward the fence  106 . 
     As the power tool  108  moves toward the fence  106 , the coiled power cord  204  is gathered into the power cord receptacle  200  to ensure the power cord  204  does not contact the work piece or the power tool  108 . Additionally, as the extension  260  engages the work-piece, the extension  260  is pivoted upwardly away from the articulating base  170  exposing the work-piece to the saw blade (not shown). 
     As discussed above, the cutting axis defined by the power tool  108  is aligned with the pivot  180 . In order to provide a consistent cut location on a work-piece with respect to the base  102 , the pivot opening  146  is positioned such that the axis  302  intersects the guide axis defined by the fence  106  when the fence  106  is locked to the locking member  118 . Accordingly, the saw blade (not shown) will cross the guide axis at the same location regardless of the miter angle. So as to allow the entire width of a work-piece to be cut, the blade cutout  160  is positioned and shaped to allow the saw blade to cross the guide axis defined by the side  167 . 
     While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the invention are desired to be protected.

Technology Classification (CPC): 8