Patent Description:
As shown in <FIG>, a router <NUM> (as shown in <FIG>) has been commonly used with a pattern or jig <NUM>, <NUM>, <NUM> to follow a shape or a form. Some jigs have used a bit-mounted guide bearing <NUM> to follow the shape, and some jigs have used the base of the router, or a collar around the bit, to follow the inside or outside of a pattern. These have all been one-to-one ratio router guide systems where the pattern <NUM>, <NUM> has been the same size, or has allowed the same travel, as the desired carved or cut pattern or shape in the workpiece.

A Hybrid PantoRouter™, PantoRouter™ <NUM> shown in <FIG>, and other router systems, have used a router to make cuts in wood, plastic and soft metals. The bit <NUM> for such a router <NUM> typically spins at up to ~<NUM>,<NUM> RPM and is often difficult to precisely control using conventional, manually-operated, methods and commonly available jigs and templates. Templates and template holder systems available to date, such as those from JDS Multi-Tools or Rockler Woodworking and Hardware, have been manufactured and sold in fixed sizes and shapes and have not allowed the degree of fine adjustment provided by the present invention to compensate for slightly different router bit diameters, for example as may have been encountered from one bit manufacturer to another, to allow for desired glue space, or to compensate for different wood species. The manufacturer of the JDS Multi-Tools and Rockler Woodworking and Hardware jigs have offered different templates of slightly different sizes, but no other system has been provided by the prior art to allow simple micro-adjustment of a router like that of the present template system.

A common method of alignment of a workpiece on a mount or table has been to measure the thickness of the workpiece using a scale or caliper, after which the user, or operator, has moved the router or mount to center the desired joint or shape on the workpiece. With this common method, there have often been required multiple test cuts and fine-tuning before a cut has been accurately centered. Of course, a downside of such a system has been wasted material, uncertainty in the process of cutting, and this has also resulted in a final product that has frequently not been as precise as would otherwise have been desirable. This in turn has led to woodworking joints, for example, such as mortise and tenon, dovetail, and box joints, that have not been as durable and have not been as accurately-fitting as would otherwise have been desirable. Or, to attain the same level of precision as the present invention would have taken much longer for set-up and multiple test cuts.

Further, while many prior art templates available today have been factory-supplied and are of good quality, nevertheless imperfections in such factory-supplied templates as shown at <NUM> on <FIG>, or in custom-made templates, have been transferred to the cut or carving at full scale. This in turn has provided a lower quality, less durable, or slower output in design and functionality than would otherwise have been desirable. <CIT> discloses a a router guide template comprising: a base portion; a top portion; an interior surface interconnecting said base portion and said top portion along an inner periphery of the template, wherein said interior surface is continuously tapered between said base portion and said top portion adapted to enable adjusting the depth of the guide on the taper on the template for adjustments to the size of cuts and carves to facilitate joinery cuts and carves with a single template, and wherein said base portion is adapted for removable and adjustable interconnection with a template holder.

A PantoRouter™-type system is advantageous over the prior art, since the aforementioned imperfections in a template are minimized by a reduction in scale of cutting movements, and hence such a system enables a cleaner and more precise cut. And a cleaner, more precise cut, results in a more pleasing, accurate and durable resulting workpiece joinery.

The invention defined in claim <NUM> addresses the problems of prior art router template systems, and it contributes to a more accurate, efficient, pleasing appearance and faster cut on a workpiece, as well as safer operating environments for operators. The invention may be preferably used with a pantographic-type router mount with a <NUM>:<NUM> mechanical advantage over the router, and this mechanical advantage gives the operator control and precision superior to any other manually-controlled means of operation.

There is provided a tapered relationship between a template and a guide bearing for following the template, wherein preferably the templates, or template, are mounted on a moveable template holder system, or armature, mounted on a moveable or stationary carriage, and wherein preferably the guide bearing, for following the template, is located on a pantographic mount.

There is provided a template which is stepped and/or tapered, as defined in claim <NUM>, to allow micro-adjustments to cuts, or carvings, in the workpiece to allow greater precision, for example as in joining two workpieces together. Thus, the guide bearing can be moved up or down (in or out on) the steps or taper on the template, which creates a larger or smaller cut in the workpiece by the router bit.

Thus, in accordance with the invention, there is provided a router guide template as defined in claim <NUM>.

The stadium shape is a geometric figure consisting of a rectangle with top and bottom lengths a, and the ends of which are capped off with semi-circles of radius r. The area of a stadium is therefore given by A = π r2 + <NUM> r a, and the perimeter by p = <NUM> (π r + a). While a stadium-shaped template, with a stadium-shaped outer periphery and a stadium-shaped inner periphery, or stepped inner periphery, is commonly, and even preferably employed in mortise and tenon joinery creation, it will be appreciated that other shapes, such as elliptical, circular, square, round, curved, or other shape appropriate to the desired design outcome, whether for joinery or otherwise, may also be employed. Therefore, where stadium is mainly used herein to describe the shapes of the outer and inner peripheries of templates herein (and stadium may be interchangeably used with elliptical herein as pertaining to the drawings), it will be appreciated that elliptical, circular, square, or other basic shapes in accordance with a desired design outcome, whether for joinery or otherwise, may also be substituted.

Combining the outside surface (tenon template) together with the inside surface (mortise template) in a single template allows the operator to cut both mortise and tenon joints using the same setup, unlike prior art templates, which have required multiple additional steps (and therefore increased errors and time to set up) by an operator to achieve the same result.

In an alternative arrangement not claimed, further comprising both an exterior surface and an interior surface formed by concave stepped-bowl-like edges and a base portion, where the interior surface actually comprises stepped interior surfaces, each surface forming in cross section a stadium (to form larger (upper) and smaller (lower) stadiums having partially concentric end portions) in cross section and having a larger circumference upper interior surface preferably at least at ends of the stadium shape thereof, and a smaller circumference lower interior surface also forming an inner stadium in cross section. In this embodiment, preferably an intermediate portion (i.e., the longer edges of the stadium bowl-shaped interior) of the interior surfaces forming the stadium-shaped concave, stepped-bowl-like edges are preferably the same width for both the upper interior surface and the lower interior surface, but there preferably is a step at each end in the interior portion of this embodiment of the template which is formed in between the two interior surfaces at each end of the stadium-bowl-shaped interior surfaces. This configuration of template allows the creation of a mortise having a larger or smaller width to allow more or less adjustability of the mortise and tenon joint.

Further, in an embodiment, one or more of the stepped interior surfaces may also be tapered.

Referring back to the first embodiment described above in accordance with this aspect of the invention, both the exterior surface and the interior surface of the router guide template may be tapered between the base portion and the top portion, and in this case at least a portion of the exterior continuous surface may be continuously tapered inwardly from the base portion to the top portion, and further in such a case where the interior surface is also tapered, a portion of that interior tapered surface may also be tapered outwardly from the base portion to the top portion.

The taper of the router guide template of this aspect of the invention comprises a continuously-tapered exterior surface. A portion of the interior surface of such a router guide template may also be tapered. Further, the tapers may extend around the entire exterior and/or interior peripheries, respectively, of the template.

It will be appreciated that different bit diameters used in a router impact the size of a template to be used. Thus, it is commonly understood by those skilled in the art that to determine template size, the formula for determining the template size for a Tenon equals <NUM>(Tenon Width + Bit Diameter) + Guide Bearing Diameter, whereas the formula for determining the template size for the Mortise equals <NUM>(Mortise Width - Bit Diameter) - Guide Bearing Diameter. Further, it will be appreciated that the router guide template tapers preferably comprise a taper of between. <NUM> degree and <NUM> degrees to allow for micro-adjustment of cuts and carvings.

The tapered templates in accordance with this aspect of the invention on the pantographic mount are precisely calculated but approximately double the desired cut so that any imperfection in the template is translated only half-scale to the workpiece, and router control requires less (approximately half) the effort, which as described further below is safer and more accurate. Thus, not only are imperfections in a template minimized to the degree of <NUM>:<NUM> in the final product of the workpiece, but the <NUM>:<NUM> mechanical advantage in the pantograph system further facilitates the ease and safety with which an operator can perform cutting and carving operations using such a system. This is in part because, in fact, there is even a greater mechanical advantage than <NUM>:<NUM> that is achieved with a pantograph-type router system comparing the operator handle relative to the cutting blade output. Thus, the tapered templates provided in accordance with this aspect of the invention serve to facilitate the ease, accuracy and increased safety of routing operations with their use in connection with a pantograph-type router system.

A guide bearing itself can also be tapered to be used with non-tapered templates, or tapered templates, to also allow micro-adjusting of the size and location of a cut or carve on the workpiece upon moving of the guide bearing relative to the template and template holder, or the template holder and template relative to the guide bearing, to also allow micro-adjusting of the size and location of the cut or carve on the workpiece. Thus, there is provided a router template guidance system having a combination guide bearing and guide template comprising: a template comprising an upper portion, a lower portion, and at least one exterior surface interconnecting the upper portion and the lower portion, said template further comprising at least one interior surface interconnecting the upper portion and the lower portion of the template; and a guide bearing comprising an exterior surface having a taper thereon adapted for following in contact with the exterior surface and the interior surface of the template.

The taper of said guide bearing exterior surface extends around the entire exterior guide bearing roller surface and is adapted for contact use with the interior and exterior surfaces of the template to guide a router blade for creating a tenon on a workpiece corresponding with the interior of the template, and for creating a mortise on another workpiece corresponding with the exterior of the template, the tenon and the mortise being matched in size and location on the workpieces in order to interconnect the workpieces.

In accordance with another aspect of the invention, , a template holder may be provided in combination with the router guide template, the template holder having a plurality of support post members, preferably two such post members at either end of the cross member (to allow clearance of a router motor in-between the post members), and a cross member interconnecting the support post members and having a plurality of linear keyed slots therein, wherein the base portion of the template is adapted for removable and adjustable interconnection with the linear keyed slots of the cross member of the template holder. Thus, in accordance with this aspect of the invention, the tapered templates are able to be mounted adjustably and removably on one or more of the template holder's plurality of keyed slots or tracks. Into one or more of these cross member keyed slots, the invention may provide that one or more adjustable keyed portions (i.e., an expanded head or nut on the end of a threaded bolt passing through the base portion of each template) and alignment guides (i.e., tapered tenons) on the base portion (i.e., a back portion) of each template may be removeably and slideably placed and tightened or loosed. This is similar to a keyed tongue and groove type relationship between each template and the keyed slots of the template holder cross member, to allow substantial adjustability of each template on the template holder. The keyed portions of each template are thus able to be tightened or loosed, by fixing or loosening, respectively, the keyed portion of each template as by screwing the threaded post within the template base, to be able to fix, or install, adjust or remove, a template relative to one or more of the tracks on the template holder. The readily adjustable tapered templates of the foregoing aspects of the invention allow for greater ease of use of the router to accomplish desired, and more accurate, cuts on a workpiece.

In accordance with another aspect of the invention, a thickness gauge for allowing the operator to quickly, accurately and easily center the height of cuts in a Y-axis on a workpiece may be located on the template holder support post, or cross-member (see <FIG> for an axis diagram for orientation references for this specification). Thus, the operator is allowed to insert the workpiece, or sample stock of a same thickness as the workpiece, further allowing the operator to lock the template holder in place and to automatically center the cut, j oint or shape in the workpiece, in order to properly adjust the desired height of the router cutting blade relative to the workpiece before beginning cutting operations. The thickness of the workpiece or sample measured by the gauge is doubled in a <NUM>:<NUM> Pantograph system so that imperfections in the surface are translated at half-scale to the workpiece, thus improving precision of cuts and carves on the workpiece.

Thus, in accordance with this aspect of the invention, the template holder of the router guide template system may further comprise a thickness gauge for use with a <NUM>:<NUM>-ratio-type, pantograph-type router system. The thickness gauge of this aspect of the invention is for enabling centering cuts and carvings in a Y-axis of a workpiece, the thickness gauge preferably further comprising a plurality of clamps on one of the cross member or the support posts. The thickness gauge of this aspect of the invention may be adapted for holding a sample of stock that is the same thickness as the intended workpiece such that the cutting blade of the router is adapted to be positioned so as to create one or more of a mortise and a tenon in a center location of the workpiece and another workpiece.

In accordance with yet another aspect and embodiment of the invention, each tapered template may be provided in a plurality of segments, wherein multiple segments of tapered templates may be mixed, matched, and combined to form differing shapes and sizes of cuts. Thus, in accordance with this aspect of the invention, there is provided a router guide template, wherein the template may be comprised of a plurality of segments of tapered templates. Further, each such segment of tapered template may comprise a top portion, a base portion, and at least one of an exterior continuously-tapered or stepped surface interconnecting the base portion and the top portion along an outer periphery and an interior continuously-tapered or stepped surface interconnecting the base portion and the top portion along an inner periphery. Still further, each such segment of tapered or stepped template may further comprise two mating end portions such that the plurality of segments of tapered templates may be removably and adjustably attached to the template holder in end-to-end fashion. When combined in this manner, the top portions, the base portions, any exterior continuously-tapered surfaces and interior continuously-tapered surfaces of each segment may be mated end-to-end with an end of another segment forming a continuous top portion, a continuous base portion, and one of an exterior continuously-tapered surface and an interior continuously-tapered surface between each mated segment. When the entire plurality of segments are thus mated end-to-end together they may form a complete router guide template with a continuous top portion, a continuous base portion, and at least one of an exterior continuously-tapered or stepped surface, and an interior continuously-tapered, non-tapered, or stepped surface. This aspect of the invention further supports and enables greater ease and flexibility in forming templates to accomplish a wider range of joining, or decorative, cuts in the workpiece.

In accordance with one or more aspects of the invention provided above, in an embodiment of the invention, there may be provided: A pantograph-type woodworking router guide template and template holder combination, comprising: a template holder comprising a plurality of post members having at least one keyed slot defined along and extending at least a portion of the length of each post member and adapted for interconnection with a pantograph carriage, the template holder further comprising at least one cross member adjustably interconnecting the plurality of post members, the template holder cross member further comprising means for removeably retaining at least one template, wherein the template holder further comprises a plurality of clamps for adjustably fixing the cross member relative to the posts; a template having a base portion and a top portion, the template further comprising exterior and interior continuous surfaces interconnecting the base and top portions of the template along an outer periphery and an inner periphery of the template, respectively, the base portion being adapted for removable and adjustable interconnection with the cross member of the template. The post members of the template holder are typically connected to the carriage of the pantograph with a plurality of bolts.

In accordance with an alternative, embodiment of one or more of the foregoing aspects of the invention, there may be provided a pantograph-type woodworking router guide template and template holder combination, wherein the interior surface and exterior surface further comprises a stepped interior surface having a larger circumference upper interior surface and a smaller circumference lower interior surface. This configuration allows the creation of a larger or smaller mortise to allow for adjustment of the tenon in the mortise.

Preferably, in accordance with an embodiment of a pantograph-type woodworking router guide template and template holder combination the exterior continuous surface is tapered and the stepped interior continuous surface may be one of non-tapered or tapered.

Further, in a pantograph-type woodworking router guide template and template holder combination, both the exterior continuous surface and the interior continuous surface are tapered, wherein the exterior continuous surface is tapered inwardly from the base portion to the top portion, wherein the interior continuous surface is tapered outwardly from the base portion to the top portion, and wherein the taper of each of the continuously-tapered exterior and interior surfaces extends around the entire exterior and interior peripheries, respectively, of the template.

In connection with this pantograph-type woodworking router guide template and template holder combination, each of the exterior continuous surface and the interior continuous surface may be continuously tapered or stepped, and the taper or step of each of the continuously-tapered or stepped exterior and interior surfaces may extend around the entire exterior and interior peripheries, respectively, of the template.

However, as described in connection with interior stepped surfaces above in connection with another embodiment and aspect of the invention, the interior of this embodiment and aspect of the invention may be tapered or non-tapered. Thus, where the interior surface may be tapered or non-tapered, the stepped interior surface and the base portion together forms a concave, stadium-bowl-shaped interior in the case of a stadium-shaped template common for creating mortise and tenon-type joinery. Thus, in this latter embodiment, the interior-concave-stadium-bowl-shaped end portions of the interior portion of the template are stepped.

And, thus, in an alternative arrangement, further comprising both an exterior surface and an interior surface formed by concave stepped-bowl-like edges and a base portion, where the interior surface actually comprises stepped interior surfaces, each surface forming a stadium (to form larger (upper) and smaller (lower) stadiums having partially concentric end portions) in cross section and having a larger circumference upper interior surface preferably at least at ends of the stadium shape thereof, and a smaller circumference lower interior surface also forming an inner stadium in cross section. In this embodiment, preferably an intermediate portion (i.e., the longer edges of the stadium bowl-shaped interior) of the interior surfaces forming the stadium-shaped concave, stepped-bowl-like edges are preferably the same width for both the upper interior surface and the lower interior surface, but there preferably is a step at each end in the interior portion of this embodiment of the template which is formed in between the two interior surfaces at each end of the stadium-bowl-shaped interior surfaces. This configuration of template allows the creation of a mortise having a larger or smaller width to allow more or less adjustability of the mortise and tenon joint. In this alternative embodiment, one or more of the stepped interior surfaces may also be tapered, elliptical, square, round, curved, or other shape appropriate to the desired design outcome, and whether for joinery cuts or otherwise.

Further, the opposing exterior and interior continuous surface tapers may be generally corresponding and opposed to each other, such that an innermost portion of the exterior and interior continuously-tapered surfaces near the top of the template (as well as near the base of the template and also in-between the top and the base of the template) may generally correspond so as to generally guide the operator in cutting and carving.

Still further, preferably in connection with this embodiment of the invention, the cross member interconnecting the support post members may define a plurality of linear keyed slots, and wherein the base portion of the template is adapted for removable and adjustable interconnection with the linear keyed slots of the cross member of the template holder.

Still further, preferably, in connection with this embodiment of any of the foregoing aspects of the invention, the template holder may further comprise a thickness gauge on a <NUM>:<NUM>-ratio-type, pantograph-type routing woodworking system, for enabling centering cuts and carvings in a Y-axis of a first workpiece, the thickness gauge further comprising a plurality of clamps on one of the cross member or the support posts and adapted for holding a sample of stock that is the same thickness as the intended workpiece such that the cutting blade of the router is adapted to be positioned so as to create one of a mortise and tenon in the center of the workpiece and another workpiece.

Further, in accordance with yet another alternative embodiment of the invention in accordance with any of the foregoing aspects of the invention, the template may be comprised of a plurality of segments of tapered templates, wherein each segment of tapered template comprises a top portion, a base portion, an exterior continuously-tapered surface interconnecting the base portion and the top portion along an outer periphery, and an interior stepped surface interconnecting the base portion and the top portion along an inner periphery, and wherein each segment of template further comprises two mating end portions such that the plurality of segments of tapered templates may be removably and adjustably attached to the template holder in end-to-end fashion such that the top portions, the base portions, the exterior continuously-tapered surfaces and the interior stepped surfaces of each segment mated with an end to another segment end forms a continuous top portion, a continuous base portion, a continuous exterior continuously-tapered) surface and an interior stepped surface, and such that when the plurality of segments are mated end-to-end together they form a complete router guide template with a continuous top portion, a continuous base portion, a continuous exterior continuously-tapered surface, and an interior stepped surface.

The tapered-template system in accordance with one or more aspects and embodiments of the invention summarized above addresses the problem of inaccurate or complicated joinery using a router and fixed-size guides or templates, thus enabling quicker, more accurate, safer, and easier-to-make joinery cuts, whether dovetail, mortise and tenon, or box joint cuts. No other known system provides similar micro-adjustment as provided with the tapered templates of the present invention. With such a system of the present invention, an operator is enabled in adjusting the depth of the guide bearing on a pantograph-type router, moving it in or out to engage a different portion of a taper on either or both an exterior surface and an interior surface of a template, to enable easy-to-make and precise joinery cuts.

Further, the tapered-template system in accordance with one or more aspects and embodiments of the invention summarized above enables users in easy and quick micro-adjustments to proposed cuts and carves.

Still further, the tapered-template system in accordance with yet another aspect of the invention enables operators to more quickly and easily center the thickness (Y-axis) of a joint or shape in a workpiece. Thus, one or more of the foregoing aspects and embodiments of the invention helps users to more quickly and accurately center their work on an intended workpiece.

With the use of the tapered-template system in accordance with one or more aspects and/or embodiments of the invention, operators are enabled in greater control over routers using a pantographic or non-pantographic router mount, thus making such template-guided routers easier to use and more accurate.

The tapered template system in accordance with one or more aspects and embodiments of the invention enables operators in installing and changing templates and template holders, thus facilitating the work of setting up, creating, and taking down, a project.

The subject matter of the present invention is particularly pointed out and distinctly claimed in the concluding portion of this specification. However, both the organization and method of operation, together with further advantages and objects thereof, may best be understood by reference to the following descriptions taken in connection with accompanying drawings wherein like reference characters refer to like elements.

In consideration of the following detailed description of various embodiments, the invention may be more completely understood in connection with the following drawings.

Referring specifically to <FIG> and <FIG>, a template holder system <NUM> in accordance with one or more aspects of the invention preferably comprises a plurality of stands, or posts, <NUM> (preferably there are provided two such posts), and preferably a single cross member <NUM> interconnecting the two posts. The template holder system <NUM> may be comprised of a single post <NUM> and cross member <NUM>, or more posts <NUM> may be employed as well. However, it will be appreciated by those skilled in the art that two such posts is preferable from the standpoint of simplicity of use, rigidity and sturdiness of the resulting template guide system <NUM>.

Each of the posts <NUM> of the template holder system <NUM> preferably has key slots, or grooves, <NUM> therein for facilitating alignment of the cross-member <NUM> thereon, for facilitating the adjustment of the template holder for use as described further hereafter for height adjustment, as well as for attaching the posts with bolts (four bolts for each post) to holes <NUM> in the router or pantograph mount <NUM> (<FIG>).

The cross-member <NUM> of the template holder system <NUM> comprises measurement indicia <NUM> on an upper edge surface <NUM>, and/or lower edge surface <NUM>, thereon, either inch or metric scale, to assist with centering, or otherwise locating, a tapered template <NUM> on the template holder in order to allow correspondingly-located cuts on workpieces. Indicia <NUM> may also be provided on the posts <NUM> as well, in order to facilitate measurement of the cross member <NUM> and height guide <NUM> position, as discussed further below, relative to the posts <NUM>.

The cross-member <NUM> of the template holder system <NUM> further preferably comprises three or more horizontal mounting grooves, or keyed slots, <NUM>, made either of plastic or metal, such as aluminum. Each of the templates <NUM>, <NUM>' (as well as other templates described herein) have corresponding tapered tenons, or tapered tongues, <NUM> to help orient and fix the templates in the keyed slots. The taper of each of these orienting tenons <NUM>, <NUM>' is provided as slightly larger at a base of each tenon than at a tip of each tenon, as shown in <FIG>, so that upon placement and tightening of the template <NUM>, <NUM>' onto the template holder <NUM> as further described below, the templates are snugly attached fixed in the slots <NUM> of the template holder.

These tapered tenons <NUM> may be oriented longitudinally the length of the template <NUM> as shown in <FIG>, the keyed slots <NUM> are preferably spaced about <NUM>/<NUM> inch, or about <NUM>, apart which provides optimal spacing for the templates <NUM>, <NUM>' in order to place single or multiple ½", <NUM>/<NUM>", or ¼" (<NUM>, <NUM>, or <NUM>) thick mortise and tenon joints in dimensional lumber common to North America, such as 2X4, 2X6, 2X8, etc. The template holder <NUM> also accommodates non-tapered, tapered or stepped templates, as further described herein in accordance with one or more aspects of the invention, to make fixed or variably-spaced dovetail and box joints. The tapered templates <NUM> may be tapered on the exterior and interior surfaces to allow micro-adjustment of the joinery.

The template holder <NUM> further comprises an L-shaped side angle system <NUM> mounted, as with screws to each side of the template holder cross member <NUM>, and the template holder cross member is partially retained within, and maintained squared relative to, the two L-shaped side angles by an outer vertically-oriented lip <NUM> on each L-shaped angle and engaging either end of the cross member. The L-shaped angle system <NUM>, comprises left and right such L-shaped angles on either side of the template holder cross member. The L-shaped angles <NUM> and cross member <NUM>, are removably fixed together with tightening screws so that the L-shaped angles and cross member combination is fixed together and adjustable as a unit, and alternatively able to be fixed, or locked at a certain height, relative to the posts <NUM> with the use of clamps <NUM>, each clamp having a tightening lever <NUM>.

The angles <NUM> and cross member <NUM> combination are able to be adjusted to an appropriate height according to indicia <NUM> on one of the posts <NUM>, the workpiece used temporarily for a height measurement as further described below, or a representative sample workpiece of the same thickness as the workpiece. Thus, the system of clamps <NUM> each have a tightening lever <NUM> for the operator to actuate to adjust the template holder cross member <NUM> position relative to the posts <NUM>, the pantograph carriage <NUM>, and thus the workpiece, via the L-shaped angles <NUM> fixed to the template holder cross member.

Thus, there is also provided a height measurement clamp, or thickness gauge, <NUM> for holding a reference, or sample, workpiece/stock <NUM>, to allow simple adjustment of the height of the cross member <NUM> and attached template <NUM> relative to the cross member, the routing table <NUM>, and thus the actual workpiece on which cutting or carving is to be performed. The thickness gauge <NUM> allows the operator to quickly, accurately and easily center a cut or carving in the Y-axis of an actual workpiece (see <FIG> for an axis diagram for proper orientation for this specification).

This is accomplished by first referencing the upper surface of the thickness gauge <NUM> at the cutting table surface, and then by adding the sample/workpiece stock <NUM>, followed by moving the cross member <NUM> (via the L-shaped angles sliding along the posts <NUM>) down so that an underside of the cross member <NUM> comes to rest on the upper surface of the reference stock <NUM>. Thereafter, the operator is able to fix the cross member <NUM> at that location using the levers <NUM> of clamps <NUM> which thus clamp the L-shaped angles <NUM> and attached cross member <NUM> to the posts <NUM> at the desired height. The thickness gauge <NUM> is built into the template holder system <NUM>, preferably mounted on a template holder support post <NUM>, or cross member <NUM>. Thus the thickness of the workpiece or sample is measured by the gauge <NUM> to accurately position or center the joinery on the workpiece.

The clamps <NUM> are both for adjusting the template holder <NUM> and operating the cross member <NUM> and L-shaped angles <NUM> combination relative to the thickness gauge <NUM>. The thickness gauge <NUM> is attached, and independently slides into, and is held in place within, the grooves <NUM> in the posts <NUM>, via a screw 27a. The side angle assembly <NUM> must be aligned on entry into the groove <NUM> in the posts <NUM>, and upon tightening of the clamp <NUM> via the lever <NUM>. Therefore a part of the invention offsets the clamps <NUM> so one may be aligned at a time. This makes changing template holders <NUM> easier and faster. Thus the template holder and system <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, as well as inventive parts, combinations and other embodiments thereof, enables operators to more quickly and easily center the thickness (Y-axis) of a joint or shape in a workpiece. Thus, this aspect, or these aspects, of the invention helps users to more quickly and accurately center their work on an intended workpiece and allows for greater precision in cuts and carves.

Referring more specifically now to <FIG>, there is provided one or more tapered templates <NUM> (other embodiments, including non-tapered templates, stepped templates, segmented templates, and other types of templates, are discussed hereafter in connection with other figures). Each tapered template <NUM> comprises a top portion <NUM>, a base portion <NUM>, and one or more continuously-tapered surfaces, exterior, outer continuously-tapered surface 32a, and interior, inner continuously-tapered surface 32b, interconnecting the top portion and the base portion of each tapered template <NUM>. Each continuously-tapered surface 32a, 32b is continuously tapered in the sense that the surface has a continuous taper from the base portion <NUM> to the top portion <NUM>. In the case of exterior continuously-tapered surface 32a, the taper preferably extends continuously inwardly from the intersecting edge <NUM> of the base portion <NUM> and the tapered surface 32a to the intersecting edge <NUM> of the top portion <NUM> and the tapered surface 32a. Similarly, in the case of interior continuously-tapered surface 32b, the taper preferably extends continuously outwardly from the intersecting edge <NUM> of the interior continuously-tapered surface 32b and the base portion <NUM> to the intersecting edge <NUM> of the interior continuously-tapered surface 32b and the top portion <NUM>.

In this way, there is provided the ability for micro-adjustment of cuts and carves because of the fact that, to the degree there are provided tapered surfaces, they are adapted to interface in a continuously-tapered fashion with an adjustable guide bearing <NUM> (<FIG> and <FIG>) to allow for such continuously-adjustable micro-adjustment.

It will be appreciated by those skilled in the art that the templates described herein are stadium-shaped. The terms stadium and elliptical are used somewhat interchangeably herein when describing one or more of the figures. The stadium shape is a geometric figure consisting of a rectangle with top and bottom lengths a, and the ends of which are capped off with semi-circles of radius r. The area of a stadium is therefore given by A = πr2 + 2ra, and the perimeter by p = <NUM>(πr + a).

Each tapered template <NUM> is provided with a series of holes <NUM> adapted for receiving the key system <NUM> for use in releasably securing each template to the cross member <NUM> slot <NUM>. The key system <NUM> further comprises a machine screw <NUM> preferably having an allen-wrench or screw driver slot(s) operable head <NUM> thereon. In this way, each tapered template <NUM> is adapted for interchangeable interconnection with a slot <NUM> of the cross member <NUM>.

Each tapered template <NUM> is held on the slots <NUM> of the cross member <NUM> of the template holder <NUM> with the use of a releasably tightenable and adjustable key <NUM> and tapered tenon <NUM> system associated with each tapered template <NUM> as shown in <FIG>. The releasably tightenable and adjustable key <NUM> and tapered tenon <NUM> system may employ the use of multiple keys <NUM> as shown in <FIG>, or a single key <NUM>' as shown in <FIG>. In either case, the tapered tenons <NUM>, together with the key <NUM>, serve to hold the tapered template <NUM> in aligned position on, and relative to, the template guide system cross member <NUM>.

Referring now specifically to <FIG> and <FIG>, there are provided a plurality of segments <NUM>, <NUM>, <NUM> comprising together a tapered template <NUM>'. It will be appreciated that other types of templates, whether tapered, non-tapered, stepped, angular, or otherwise as discussed in other locations or in connection with other Figures in this specification, may be segmented and/or attached horizontally, vertically, or in angled orientation, to cross member <NUM> in accordance with an aspect and embodiments of the invention, without departing from the scope of the invention as claimed.

As with tapered template <NUM>, tapered template <NUM>', when considered with multiple segments fit together end-to-end, also comprises a continuous top portion <NUM>', a continuous base portion <NUM>', and one or more continuously-tapered surfaces, such as exterior, outer continuously-tapered surface 32a', and/or interior, inner continuously-tapered surface 32b', interconnecting the top portion and the base portion of each tapered template <NUM>'. Each continuously-tapered surface 32a'/ 32b' is continuously tapered in the sense that the surface has a continuous taper from the base portion <NUM>' to the top portion <NUM>'. In the case of exterior continuously-tapered surface 32a', the taper preferably extends continuously inwardly from the intersecting edge <NUM>' of the base portion <NUM>' and the tapered surface 32a' to the intersecting edge <NUM>' of the top portion <NUM>' and the tapered surface 32a'. Similarly, in the case of interior continuously-tapered surface 32b', the taper preferably extends continuously outwardly from the intersecting edge <NUM>' of the interior continuously-tapered surface 32b' and the base portion <NUM>' to the intersecting edge <NUM>' of the interior continuously-tapered surface 32b' and the top portion <NUM>'.

In this way, there is provided a tapered relationship not only between the exterior continuously-tapered surface 32a' and the interior continuously-tapered surface 32b', but there is also provided for micro-adjustment of cuts and carves because of the fact that these tapered surfaces are adapted to interface in a continuously-tapered fashion with an adjustable guide bearing <NUM> to allow for such continuously-adjustable micro-adjustment.

In <FIG>, tapered template <NUM>' differs from tapered template <NUM> in that tapered template <NUM>' is comprised of a plurality of segments <NUM>, <NUM>, <NUM>. Thus, each of the segments <NUM>, <NUM>, <NUM> has a top portion <NUM>', a base portion <NUM>', an exterior continuously-tapered surface 32a', an interior continuously-tapered surface 32b', and preferably a hole <NUM>', tapered tenons <NUM>', and key members <NUM>'. Further, each tapered template segment <NUM>, <NUM>, <NUM> also preferably has at least one cross-section end cut <NUM>, and in some cases (i.e., segment <NUM>) a plurality of cross-section end cuts. Preferably, these cross-section end cuts <NUM> will match corresponding cross-section end cuts <NUM>, so that two or more segments may be located end-to-end in the slots <NUM> of cross member <NUM> (as shown in dotted lines at <NUM>' on <FIG>) in order to form a complete template <NUM>'.

Thus, it will be appreciated that segments <NUM>, <NUM>, <NUM>, or other segments having differing shapes in order to form desired cuts on a workpiece as will be appreciated by those skilled in the art, may be mixed, matched, and combined to form differing shapes and sizes of cuts. Thus, there is provided a router guide template <NUM><NUM>', wherein the template is comprised of a plurality of segments of tapered templates <NUM>, <NUM>, <NUM>. Further, each such segment <NUM>, <NUM>, <NUM> of tapered template <NUM>' comprises a top portion <NUM>', a base portion <NUM>', and at least one of an exterior continuously-tapered surface 32a' interconnecting the base portion and the top portion along an outer periphery and an interior continuously-tapered surface 32b' interconnecting the base portion and the top portion along an inner periphery.

Still further, each such segment <NUM>, <NUM>, <NUM> of tapered template <NUM>' further comprises two mating end portions <NUM> such that the plurality of segments of tapered templates may be removably and adjustably attached to the template holder <NUM> in end-to-end fashion. When combined in this manner, the top portions <NUM>', the base portions <NUM>', any exterior continuously-tapered surfaces 32a' and interior continuously-tapered surfaces 32b' of each segment <NUM>, <NUM>, <NUM> are mated end-to-end with an end <NUM> of another segment forming a continuous top portion <NUM>', a continuous base portion <NUM>', and one of an exterior continuously-tapered surface 32a' and an interior continuously-tapered surface 32b' between each mated segment.

When the entire plurality of segments <NUM>, <NUM>, <NUM> are thus mated end-to-end together they form a complete router guide template <NUM>' with a continuous top portion <NUM><NUM>', a continuous base portion <NUM>', and at least one of an exterior continuously-tapered surface, 32a', an interior continuously-tapered surface 32b', and even a non-tapered interior or exterior surface (e.g., for example if template <NUM> or <NUM> of <FIG> were to be shown as segmented, since there are not shown guide surface tapers on these templates). This arrangement further supports and enables greater ease and flexibility in forming templates <NUM>' to accomplish a wider range of joining, or decorative, cuts in a workpiece.

Each tapered template <NUM> (<NUM>', <NUM>", <NUM>‴, <NUM>, <NUM>, <NUM>, <NUM>, <NUM>, etc.) is provided with a series of holes <NUM> adapted for receiving the key system <NUM> for use in releasably securing each template to the cross member <NUM> slot <NUM>. The key system <NUM> further comprises a threaded post <NUM> preferably with an allen-wrench (other screwdriver) operable head <NUM> thereon. In this way, each template is adapted for interchangeable interconnection with a slot <NUM> of the cross member <NUM>.

It will be appreciated that any taper of the interior and the exterior tapered surfaces of the templates (e.g., <NUM>) described herein, may beneficially extend along the entire tapered surface (depending upon the desired output of such a guided pantorouter system), both from the base portion (e.g., <NUM>) of the template to the top portion (e.g., <NUM>) of the template, as well as around the entire length, or circumference in the case of an entirely stadium, elliptical, circular or oval template. Thus, there may be advantageously provided such a taper both near the top portion (e.g., <NUM>) of the template (e.g., <NUM>), near the base portion (e.g., <NUM>) of the template, in between these two extreme locations, and along the entire tapered length of the template.

Referring now to <FIG>, there is provided a template <NUM>", according to the invention, comprised of a stepped, tapered template <NUM>", wherein, similar to tapered template <NUM>, there is provided a top portion <NUM>", a base portion <NUM>", an exterior continuously- tapered surface 32a", and stepped interior surfaces 32b" and 32c. Further, as with template <NUM>, and <NUM>', template <NUM>" also comprises alignment tapered tenons <NUM>", and a key system <NUM>", except unlike the key systems <NUM>, <NUM>' of templates <NUM>, <NUM>', respectively, template <NUM>" only has a single key system <NUM>", which together with the alignment tapered tenons <NUM>", serves to releasably hold the template <NUM>" on a cross member <NUM> slot <NUM>.

In <FIG>, there is provided yet another alternative embodiment template <NUM>''', comprised of a stepped, tapered template <NUM>‴, wherein similar to tapered template <NUM>", there is provided a top portion <NUM>‴, a base portion <NUM>''', an exterior continuously-tapered surface 32a''', and stepped interior surfaces 32b‴ and 32c'. However, unlike tapered template <NUM>", interior surfaces 32b‴ and 32c' are tapered at each of the steps. Like tapered template <NUM>", tapered template <NUM>‴ also comprises alignment tapered tenons <NUM>‴, and a key system <NUM>‴ for releasably holding the template <NUM>‴ on a cross member <NUM> slot <NUM>.

Referring now to <FIG>, there are provided alternative templates <NUM>, <NUM>, <NUM>, respectively, which are not claimed. Each such template has a key system <NUM> similar to that of tapered template <NUM>, for example, and tapered tenons <NUM>, <NUM>, <NUM>, respectively as to <FIG>. Because of the orientation of the tapered tenons <NUM>, the segmented template <NUM> would sit vertically on the cross member <NUM> similar to segmented template <NUM> shown in dotted lines on <FIG>, whereas the template <NUM> would sit at an angle on the cross member <NUM>, and the template <NUM> would sit horizontally on the cross member <NUM>.

Referring now also to <FIG> and <FIG>, this arrangement uses a router motor <NUM> (as part of a PantoRouter™, or Hybrid PantoRouter™, router system <NUM>), having a router bit <NUM> and guide bearing, or guide wheel, <NUM> held on a guide bearing shaft <NUM>" on a pantographic mount <NUM> on a base or carriage <NUM>. On the pantographic mount <NUM>, the center of the guide bearing <NUM> is located twice the distance from the reference pivot as the center of the router bit <NUM>. The guide bearing <NUM> is guided by the operator around or within a template <NUM>, <NUM>', <NUM>", <NUM>‴, <NUM>, <NUM>, <NUM>, <NUM>, <NUM> moveably located in the moveable tapered template holder system <NUM>. Using the handle <NUM> and arm <NUM> of the pantographic mount <NUM>, the operator can move the guide bearing <NUM> up or down the tapers 32a, 32b of the tapered template <NUM>, or tapers 32a', 32b' of the tapered template <NUM>', etc., which creates a larger or smaller cut in the workpiece by the router bit <NUM>. In this way, and by adjusting the depth of the guide bearing <NUM> on a taper on a template via guide bearing adjustment knob <NUM>, the operator is allowed in micro-adjusting the size of the cut or carve on a workpiece.

Of course, it will be appreciated by those skilled in the art that templates such as those shown in <FIG> may be adapted for use with all other arrangements, since these templates may be adapted in accordance with this disclosure to include tapered tenons and keys for interconnecting to a template holder. Thus, the template <NUM> shows an alternative embodiment of a template comprising an exterior stepped portion and an interior stepped portion (without showing, for purposes of avoiding redundancy, tapered tenons and keys for interconnecting to a template holder). Moreover, the template <NUM> shows a template comprising an exterior stepped portion and an interior non-tapered portion (again without showing, for purposes of avoiding redundancy, tapered tenons and keys for interconnecting to a template holder).

As shown additionally in <FIG>, guide bearings can also be tapered as shown at <NUM>' to be used with stepped templates (e.g., <NUM>" of <FIG>, or <NUM> of <FIG>), non-tapered templates <NUM>"", tapered templates (e.g., <NUM> of <FIG>), or segmented templates (e.g., <NUM>' of <FIG> and <NUM> of <FIG> and <FIG>), to also allow micro-adjusting the size of the cut or carve on a workpiece.

The invention, or certain aspects thereof, can be used in any position, including but not limited to horizontal, such as with a Hybrid PantoRouter™ and PantoRouter™, or vertical such as a pin router or similar application. The invention, or certain aspects thereof, can also be used with non-pantographic router mount devices. Thus, the template holder system in accordance with an aspect of the invention can be moved to different positions, different jigs, or with different machines.

The tapered-template system in accordance with an aspect of the invention addresses problems of safety, inaccurate joinery using a router and fixed-size guides or templates. Thus, the invention enables quick, accurate, safer and easy-to-make joinery cuts, whether dovetail, mortise and tenon, or box joint cuts.

Claim 1:
A router guide template (<NUM>", <NUM>‴) comprising:
• a base portion (<NUM>", <NUM>‴);
• a top portion (<NUM>", <NUM>‴);
• an exterior surface (32a", 32a‴) interconnecting said base portion (<NUM>", <NUM>‴) and said top portion (<NUM>", <NUM>‴) along an outer periphery of the template (<NUM>", <NUM>‴) and an interior surface interconnecting said base portion (<NUM>", <NUM>‴) and said top portion (<NUM>", <NUM>‴) along an inner periphery of the template (<NUM>", <NUM>‴), wherein said exterior surface (32a", 32a‴) is continuously tapered between said base portion (<NUM>", <NUM>‴) and said top portion (<NUM>", <NUM>‴) adapted to enable adjusting the depth of the guide on the taper on the template (<NUM>", <NUM>‴) for adjustments to the size of cuts and carves to facilitate joinery cuts and carves with a single template, wherein said base portion (<NUM>", <NUM>‴) is adapted for removable and adjustable interconnection with a template holder (<NUM>) and wherein said interior surface further comprises a plurality of stepped interior surfaces (32b", 32c, 32b‴, 32c'), an upper interior surface (32b", 32b‴) generally describing in cross section a stadium shape having first and second ends and an elongated middle portion and a lower interior surface (32c, 32c') generally describing in cross section a stadium shape having first and second ends and an elongated middle portion, wherein at least the ends of said lower interior surface (32c, 32c') comprise a smaller circumference surface than at least the ends of said upper interior surface (32b", 32b‴) such that an intermediate step is formed at least adjacent the ends of and between the upper interior surface (32b", 32b‴) and the lower interior surface (32c, 32c').