Abstract:
A band saw includes a first wheel and a second wheel for supporting a continuous band saw blade, a motor operable to drive at least one of the first and second wheels, a housing supporting the first wheel and the second wheel, a shoe for engaging a workpiece, the shoe including a first detent feature. The band saw also includes a second detent feature cooperating with the first detent feature to hold the shoe with respect to the housing. The shoe is moveable with respect to the housing between an engaged position and a non-engaged position. The shoe is moveable out of the engaged position by application of a force acting to move the shoe with respect to the housing sufficient to overcome cooperation between the first and second detent features in the engaged position.

Description:
RELATED APPLICATIONS 
       [0001]    This application is a continuation of co-pending U.S. patent application Ser. No. 12/508,824 filed on Jul. 24, 2009 which claims priority to U.S. Provisional Patent Application Ser. No. 61/083,703 filed on Jul. 25, 2008, and this application is also a continuation of co-pending U.S. patent application Ser. No. 12/794,023 filed on Jun. 4, 2010 which is a continuation-in-part of U.S. patent application Ser. No. 12/508,824 filed on Jul. 24, 2009 which claims priority to U.S. Provisional Patent Application Ser. No. 61/083,703 filed on Jul. 25, 2008, the entire contents of all of which are incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to workpiece locators for power tools, and more particularly for band saws. 
         [0003]    A band saw typically includes a drive wheel pulley, a motor coupled to the drive wheel pulley to drive the drive wheel pulley, a driven wheel pulley, and a continuous band saw blade looped around the drive wheel and the driven wheel. Band saws may also include a shoe to locate a workpiece with respect to a cutting portion of the band saw blade. The workpiece may be large or small and take on many various shapes. To remove the shoe or adjust a position of the shoe depending on the workpiece or type of cut to be made, a user uses a tool to release the shoe from a first position and secure it in a second position. 
       SUMMARY 
       [0004]    In one aspect, the invention provides a band saw. The band saw includes a first wheel and a second wheel for supporting a continuous band saw blade, a motor operable to drive at least one of the first and second wheels, and a housing supporting the first wheel and the second wheel. The band saw also includes a shoe for engaging a workpiece, the shoe including a first detent feature. The band saw also includes a second detent feature cooperating with the first detent feature to hold the shoe with respect to the housing. The shoe is moveable with respect to the housing between an engaged position in which the first and second detent features cooperate to hold the shoe with respect to the housing, and a non-engaged position in which the first and second detent features do not cooperate. The shoe is moveable out of the engaged position by application of a force acting to move the shoe with respect to the housing sufficient to overcome cooperation between the first and second detent features in the engaged position. 
         [0005]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0006]      FIG. 1  is a side perspective view of a band saw including an adjustable shoe system according to one embodiment of the invention. 
           [0007]      FIG. 2A  is a bottom perspective view of the band saw of  FIG. 1 . 
           [0008]      FIG. 2B  is a top perspective view of a portion of the band saw shown in  FIG. 1 . 
           [0009]      FIG. 3  is an exploded perspective view of the adjustable shoe system of  FIG. 1 . 
           [0010]      FIG. 4  is a perspective view of the adjustable shoe system of  FIG. 1 . 
           [0011]      FIG. 5A  is a cross section of the adjustable shoe system taken along line  5 A- 5 A of  FIG. 4 . 
           [0012]      FIG. 5B  is a cross section of a portion of the band saw taken along line  5 B- 5 B of  FIG. 2B . 
           [0013]      FIG. 6  is a rear perspective view of the adjustable shoe system of  FIG. 1 . 
           [0014]      FIG. 7  is a cross section of the adjustable shoe system taken along line  7 - 7  of  FIG. 6 . 
           [0015]      FIG. 8  is a top perspective view of a band saw including a removable shoe system according to another embodiment of the invention. 
           [0016]      FIG. 9  is a cross section of the removable shoe system taken along line  9 - 9  of  FIG. 8 . 
       
    
    
       [0017]    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 are for the purpose of description and should not be regarded as limiting. 
       DETAILED DESCRIPTION 
       [0018]      FIGS. 1-7  illustrate a band saw  10  and an adjustable shoe system  91  embodying some aspects of the invention. An AC version of the band saw  10  having an electrical connection cord  12  is illustrated; however, in further embodiments, DC versions of the band saw  10  including a rechargeable, removable battery pack are possible. 
         [0019]    The band saw  10  includes a housing or frame  14  supporting a motor  18  and a gear box  22 . The motor  18  is drivingly connected to a drive mechanism (not shown) at least partially housed within the gear box  22 . The motor  18  and the drive mechanism are operable to drive a continuous band saw blade  26  to cut a workpiece. As described herein, the band saw  10  includes a front  30  and a rear  34 . The front  30  is defined as the side being proximate the portion of the band saw blade  26  that cuts the workpiece and the rear  34  is defined as the side proximate the portion of the band saw blade  26  that does not cut the workpiece. The rear  34  is otherwise described as being opposite the front  30 . 
         [0020]    The housing  14  includes a main handle  38  supporting a switch assembly  42  to provide power to the band saw  10 . The switch assembly  42  is operable to control operation of the motor  18 . The band saw  10  also includes an auxiliary handle  46  for a user&#39;s other hand spaced from the main handle  38 . Generally, the handles  38 ,  46  are shaped and arranged for two-handed operation of the band saw  10  as the workpiece is cut. In the illustrated construction, each handle  38 ,  46  has an ergonomic design to provide comfortable gripping and controlled operation of the band saw. The ergonomic design of each handle and of the combination of the handles may include the orientation or angle of handle(s). The ergonomic design may also include the use of material, such as an elastomeric material, on the handle(s) to, one or more of, provide an improved grip surface, isolate vibration and impacts from the operator, prevent heat build-up and/or transfer to the operator, etc. 
         [0021]    The housing  14  defines a first portion  50  and a second portion  54 . The first portion  50  and the second portion  54  are spaced apart from one another and define a U-shaped cavity  66  defining a cut zone  58  therebetween. A blade guard  62  ( FIG. 2A ) is positioned at the rear  34  of the band saw  10  and extends between the first and second portions  50 ,  54  within the cut zone  58 . The blade guard  62  provides a recessed area to house the band saw blade  26 . 
         [0022]    As shown in  FIG. 2A , the drive mechanism generally includes a drive wheel pulley  70  and a driven wheel pulley  74 . The drive wheel  70  rotates about a drive wheel axis  78  defined by a drive wheel axle  79  and is drivingly connected to the motor  18  via a drive train (not shown). The driven wheel  74  rotates about a driven wheel axis  82  defined by a driven wheel axle  83  and is rotatably supported by the housing  14 . The drive wheel  70  is positioned in the first portion  50  of the housing  14 , and the driven wheel  74  is positioned in the second portion  54  of the housing  14 . A wheel tire  86  is coupled to each of the peripheries of the drive wheel  70  and the driven wheel  74 . Each wheel tire  86  is a circular-shaped ring formed of a soft and/or flexible elastomeric material that is able to lock or adhere to the respective wheel  70 ,  74 . The band saw blade  26  extends around the drive wheel  70  and the driven wheel  74  and grips the blade tires  86  and, as a result, motion from the drive wheel  70  is transmitted to the band saw blade  26  via the blade tires  86 . The band saw  10  also includes a blade tensioning mechanism  90  to adjustably provide appropriate tension on the band saw blade  26 . 
         [0023]    A first guide roller set  110  and a second guide roller set  114  are disposed on each side of the cavity  66  and engage opposing sides of the saw blade  26 . The first and second guide roller sets  110 ,  114  support the band saw blade  26  as the blade  26  enters and exits the cut zone  58 . 
         [0024]    The band saw  10  also includes an adjustable shoe system  91  including a shoe  92  for positioning against the workpiece, a connector block  96  for coupling the shoe  92  to the housing  14 , and a detent mechanism  161  ( FIGS. 5A and 5B ) for holding the shoe  92  in select positions relative to the connector block  96 . The shoe  92  is coupled to the housing  14  by way of the connector block  96  and the detent mechanism  161 . 
         [0025]    With reference to  FIGS. 2A-7 , the connector block  96  is a generally T-shaped member coupled to the housing  14  by fasteners  138 . The connector block  96  is coupled to the first portion  50  of the housing  14  adjacent the drive wheel  70  and is positioned in or adjacent the cavity  66  at an end of the cut zone  58 . The connector block  96  includes fastener apertures  142  through which the fasteners  138  are disposed to couple the connector block  96  to the housing  14 . In the illustrated construction, two fastener apertures  142  ( FIG. 5A ) and two screws  138  ( FIG. 5B ) are employed. In other constructions, fewer or more fasteners and fastener apertures may be employed to couple the connector block  96  to the housing  14 , or the connector block  96  may be integrally formed with the housing  14 . 
         [0026]    The connector block  96  includes a main body portion  146  and first and second extending portions or flanges  150 ,  154  generally forming a T-shape, as shown in  FIG. 7 . In the illustrated embodiment, the main body portion  146  is positioned adjacent the housing  14  and engages the housing  14  when the connector block  96  is fastened to the housing  14 . The main body portion  146  includes first and second pins  170 ,  174  extending therefrom for locating the connector block  96  with respect to the housing  14 . As illustrated in  FIG. 5B , the pins  170 ,  174  are received by apertures or recesses in the housing  14 . The first and second extending portions  150 ,  154  communicate with the shoe  92 , as described below. 
         [0027]    The connector block  96  also includes a recess or aperture  158  for receiving the detent mechanism  161  ( FIGS. 5A and 5B ). The detent mechanism  161  includes a ball detent  162  and a biasing member  166 , such as a leaf spring. The ball detent  162  is biased by the biasing member  166  to an extended position away from the housing  14  for engaging the shoe  92  and holding the shoe  92  in position with respect to the housing  14 . In other constructions, the biasing member  166  may include other types of springs and biasing members, such as a coil spring. 
         [0028]    With further reference to  FIGS. 3-7 , the shoe  92  includes a generally C-shaped body member  172  and a workpiece-engaging member  176 . The body member  172  wraps around and slideably engages the first and second extending portions  150 ,  154  of the connector block  96 . An axis  98  of the adjustable shoe system  91  is defined by the direction the shoe  92  slides relative to the connector block  96 . The axis  98  is also defined by an axis of symmetry of the body member  172 . In the illustrated embodiment, the detent mechanism aperture  158  and the fastener apertures  184  are centered on the axis  98 . The workpiece-engaging member  176  generally extends along the axis  98  below the cut zone  58  and away from the housing  14  of the band saw  10 . The shoe  92 , and in particular the workpiece-engaging member  176 , engages a workpiece (not shown) in order to secure the workpiece relative to the band saw blade  26  within the cut zone  58  during a cutting operation. The workpiece-engaging member  176  includes a groove or slot  180  in which the band saw blade  26  is positioned, as shown in  FIGS. 2A-2B . The direction of movement of the band saw blade  26  through the slot  180  is generally perpendicular to the axis  98 , and a plane of the band saw blade  26  extending through the slot  180  is generally parallel to the axis  98 . 
         [0029]    Referring to  FIGS. 2A-6 , the shoe  92  includes apertures  184  for receiving the detent mechanism  161  and holding or locating the shoe  92  in position relative to the housing  14 . The ball detent  162  is biased toward the shoe  92  and is received by one of the apertures  184  to engage the shoe  92  and hold the shoe  92  in a position corresponding to the respective aperture  184 . In the construction of  FIGS. 2A-7 , the shoe  92  includes two apertures  184  and is adjustable between a first engaged position and a second engaged position. In the first position, the ball detent  162  is received by a first of the apertures  184  and engages the shoe  92  to hold the shoe  92  in the first position ( FIGS. 2A ,  2 B, and  5 A- 6 ), i.e., to hold the shoe  92  with respect to the connector block  96 . In the second position, the ball detent  162  is received by a second of the apertures  184  and engages the shoe  92  to hold the shoe  92  in the second position. 
         [0030]    The first position is an extended position, extending away from the housing  14 , for accommodating larger workpieces. The second position is a recessed position, recessed toward the housing  14 , for accommodating smaller workpieces or cutting flush against a surface, such as a ceiling or wall. In the fully recessed position, the end of the shoe is adjacent or near a bottom edge (i.e., the cutting edge) of the band saw blade  26 . A non-engaged position includes a position in between the first and second positions. In the non-engaged position, the ball detent  162  is not received by the apertures  184 . The non-engaged position may also include a position in which the shoe  92  is removed from the connector block  96 . In other constructions, three or more apertures  184  may be employed such that the shoe  92  is adjustable between three or more positions ranging from a fully extended to a fully recessed and intermediate positions therebetween for positioning and securing the band saw  10  with respect to a variety of workpieces of varying sizes and shapes. 
         [0031]      FIGS. 8-9  illustrate a removable shoe system  178 , given the same reference numerals as the adjustable shoe system  91  shown in  FIGS. 1-7 . The removable shoe system  178  is similar to the adjustable shoe system  91  except that the shoe  92  includes only one aperture  184 . In this construction, the shoe  92  is moveable between an engaged position in which the ball detent  162  is received by the aperture  184  and a non-engaged position in which the shoe  92  is removed from the connector block  96 . The non-engaged position may also include an intermediate position in which the shoe  92  is not removed, but in which the ball detent  162  does not engage the aperture  184 . 
         [0032]    In order to adjust the position of the shoe  92 , a user applies a force on the shoe  92  in the direction of the axis  98 . The force causes the body of the shoe  92  to engage the ball detent  162  and overcome the biasing force of the biasing member  166 . The ball detent  162  is moved toward the housing  14  and engages an inner surface of the shoe  92  as the shoe  92  is moved to another position or removed. When one of the apertures  184  is positioned adjacent the ball detent  162 , the ball detent  162  is pushed at least partially into the one of the apertures  184  by the biasing spring force and engages the body of the shoe  92  surrounding the one of the apertures  184  to hold the shoe  92  in place. In operation, the shoe  92  is adjusted by applying a force on the shoe  92  in either direction along the axis  98  to move the shoe  92  to a desired position depending on the size and shape of the workpiece being cut, or to remove the shoe  92 . No tools or removal of fasteners are required to adjust or remove the shoe  92 . 
         [0033]    Although particular constructions embodying independent aspects of the present invention have been shown and described, other alternative constructions will become apparent to those skilled in the art and are within the intended scope of the independent aspects of the present invention.