Patent Document

BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The disclosure made herein generally relates to electric power tools and work benches for power tools and, more particularly, to a work station integrated with a variety of power tools and providing a work surface including a drop-in work module for a tow able trailer, thereby permitting the work module to be towed directly to the worksite with all the power tools in place, ready to use after the hinge able compartments have been extended. 
     2. Discussion of the Prior Art 
     Tradesmen and craftsmen, such as those working in the building construction and remodeling trades require a wide variety of power tools and worktables for completing projects. When starting work on a project each day, looking for and setting up power tools and equipment for use on a job site can consume a significant amount of time. Time lost in locating tools, setting up saw horses and work surfaces is unproductive. Additionally, certain task requires items to be prepared off-site to assure because of the unsatisfactory work environment. The work module would help minimize the need to fabricate off-site. 
     U.S. Pat. No. 4,055,206 to Griffin discloses a composite shop trailer. The Griffin patent includes a shop type composite trailer, which can be folded to a compact size for transport and can be expanded during shop use. U.S. Pat. No. 5,383,698 to Buchholz discloses a tool trailer with open end. The Buchholz patent includes a trailer that is fitted with power saws particularly adapted to accept long pieces of lumber for sawing. U.S. Pat. No. 6,565,165 to Switkes discloses a compact ergonomic weatherproof mobile workstation. The Switkes patent includes a composite workstation with multiple compartments, which are created by joining structural panels in perpendicular, parallel and opposing horizontal configurations. Tools and supplies are placed in the compartments formed in the composite workstation. 
     Therefore, there remains the need in the construction and remodeling industries for a mobile work station that is designed specifically to illuminate the typical issues involved with the setup and the available work bench areas to perform the normal daily task. The work module would eliminate the need for saw horses and work benches. 
     SUMMARY OF DISCLOSURE 
     Accordingly, embodiments of the inventive disclosure made herein, which disclose a drop-in work module for a wheeled vehicle such a trailer equipped to be pulled by a wheeled vehicle such as a pickup or a van. 
     The drop-in work module integrates a variety of power tools and equipment used daily in the home and commercial building industries. 
     The work module is a basic rectangular box-like structure that has foldable side rails that pivot from a stored position to a work position, which forms a large flat work surface area. 
     The work module has locking pins on the side rails, which is used to lock the side rails into position for transporting. The pins also have provisions for a security lock to be attached, which will protect all the equipment that is stored in the work module. 
     The work module includes a tailgate that serves as a set of drop down steps that pivot to a down position and will assist the user for the access to the top work surface of the work module. 
     The work module includes a dustbin under the work surface that will collect the dust particles from the saws that are mounted on the work module. 
     The work module includes a top retractable surface that exposes a dual slide saw module. 
     The work module includes a miter saw that mounts on a hinge that will pivot from a stored position to a ready to use position. 
     The work module includes a router or drill press mounted on a hinged top that pivots from a stored position to a ready to use position. 
     The work module includes storage areas for equipment/hand tools that mounts on a hinge that pivot from a stored position to a ready to use position. 
     The work module includes a pre-wired electrical service box for 120 VAC connections for all power tools. All wiring is routed and secured to the inside surface of the work module. Receptacles are also pre-wired for other power tools that may be used in conjunction with the work module. 
     The circular saw module has two saws that can accommodate various blades that may be needed for the individual work task and therefore reduces the need to change between different saw blades during the project in progress. 
     The circular saw module has a slide assembly that includes two linear rails with composite bearings, motor driven acme screw for the laterally position of the saws. 
     The circular saw module has an actuator unit which positions the saws from a stored (safe) down position to the upward saw position exposed ready for use. Actuator has an on-board limit switch to prohibit the saws from staring while in the up position. 
     The circular saw module has a rolling deck attached to the top side of the unit. This is used to cover the slide assembly for a safe working environment. 
     The work module has moveable push-lock mechanisms designed to hold the part secure for the saw module. The push-lock mechanisms are mounted on a rail, which will allow the part to be secured and move the part in straight line in relation to the saws. 
     The work module includes an electrical control drive panel, which includes the controls for the saws and the saw slide positioning. 
     The work module and electrical safety hand held pendant that allows the user to operate the saw module from various positions. 
     The work module and electrical safety foot switch that requires the foot switch to be depressed before either saw will operate. 
     The work module top supports include a U-shaped channel that also serves as a water-proof channel which routes water from the top surfaces similar to that of a rain gutter system. 
     The work module is suggested but not limited to being constructed from aluminum type materials in order to capitalize on light weight, non-corrosive and has substantial mechanical strength properties. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The drawings show a form of the invention that is presently preferred; however, the invention is not limited to the precise arrangement shown in the drawings. 
         FIG. 1  presents a perspective view of a drop-in work module in accordance with the inventive disclosures herein. 
         FIG. 2  presents a plan view of one embodiment of the drop-in work module depicting compartment layout and top surfaces covering the compartments, in accordance with the inventive disclosures herein. 
         FIG. 3A  illustrates a side view of one embodiment of the drop-in work module showing a folding side rail in a stored position. 
         FIG. 3B  illustrates a side view of one embodiment of the drop-in work module showing a folding side rail in a work position to provide flat top work surface. 
         FIG. 4  illustrates a top view of one of the embodiments of the drop-in work module depicting the top work surface in the retracted positing exposing the saw slide module without the rolling deck attached. 
         FIG. 5  illustrates a top view of one of the embodiments of the drop-in work module depicting the top work surface in the retracted positing exposing the saw slide module with the rolling deck attached. 
         FIG. 6  illustrates front view of one of the embodiments depicting the miter saw and bench router swung out in the open position for use. 
         FIG. 7  illustrates rear view of one of the embodiments depicting the left side rail raised to the stored position to be used as a fence to guide materials being cut with saw. 
         FIG. 8  illustrates a plan view of a moveable push-lock mechanism designed to secure part while it is being pushed onto the saw blade. 
         FIG. 9  illustrates a plan view of the saw slide module, which includes left/right circular saws, motor driven acme screw, saw bearing rails and the end supports. 
         FIG. 10  illustrates a side view of the saw slide module, which includes a right circular saw, the extend/retract actuator for the right circular saw. 
         FIG. 11  depicts the electrical controls system, which includes the control drive panel, pendant controls and the safety foot switch. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     In preparation for explaining the details of the present inventive disclosure, it is to be understood by the reader that the invention is not limited to the presented details of the construction materials and embodiments and of being practiced and realized in various ways by applying the disclosure presented herein. 
       FIG. 1  presents a perspective view of a drop-in work module  10  in accordance with the inventive disclosures herein. The work module  10  is depicted installed into a tow able trailer  12 . Left side rail  14  and right side rail  16  is hinge ably connected to the sidewalls of the work module  10 . A dustbin  18  for receiving sawdust from the saw  58  is positioned below the top surface  23  of the work module. The fold down tailgate,  22  drops and also serves as a steps to the top surface area of the work module  10 . Behind the tailgate  22  is a storage compartment  38  that houses the electrical drive panel  24 , the foot safety switch  28  and the pendant control  26 . An electrical service box  32  is secured to the front of the work module  10 , the service box provides the electrical supply connections for connecting the main power source to the pre-wired device within the work module  10 . 
       FIG. 2  presents a plan view of one embodiment of the work module  10  depicting compartment layout and covering top surfaces in accordance with the inventive disclosures herein. The top surface  20  (see  FIG. 1 ) includes; a dustbin top surface portion  34 , a router/drill top surface portion  36 , a dual saw slide top surface portion  42  and a storage compartment portion  40 . The optional mounting bracket for a generator/compressor is shown a front of trailer portion  44 . 
       FIG. 3A  illustrates a side view of one of the embodiments of the drop-in work module  10  showing the right side rail  16  in a stored position substantially parallel to the right sidewall  48  of the work module  10 . Locking pins  50  are operable for selectively locking the side rail  16  in the stored position. 
       FIG. 3B  illustrates a side view of one embodiment of the drop-in work module depicting the right side rail  16  in an open position providing an extended work surface. Fold down tailgate/steps  52  are hinge ably secured onto the rear of the work module  10 , the steps operable to a dropped down position wherein the steps provide the user access to the top work surface  20  (see  FIG. 1 ). In the depicted embodiment, an electrical service outlet  54  is provided in the toe side of the fold down steps  52 . 
       FIG. 4  illustrates a top view of the work surface of the work module  10 . The top surface portion  34  is shown in the retracted position exposing the saw slide module  64 . A left saw  58  and a right saw  60  are mounted on a horizontal slide mechanism  86 . The surface portion  34  is manually retracted and locks into place in preparation for the use of either saw  58  or  60 . 
       FIG. 5  illustrates a top view of one embodiment of the work module  10  depicting the rolling deck surface  56  which covers the saw horizontal slide mechanism  64  (see  FIG. 4 ). The rolling deck  56  moves horizontally with the saw slide module  64  (see  FIG. 9 ) and is a cover that protects the saw module from debris and serves as a protective device for the user by reducing the area for pinch points.  FIG. 5  also illustrates the side rails  14  and  16  in the down work position. 
       FIG. 6  illustrates a rear view of the work module  10  depicting the miter saw  68  and bench router  70  in the swung out position ready for use. The left side rail and the right side rail are shown in the full open-down position creating a flat work surface. 
       FIG. 7  illustrates a rear view of the work module  10  depicting the left side rail  14  raised to the stored position and serving as a fence so as to be operable to guide material being cut by the left saw  58  in order to provide a precise cut. The feed screw  72  (see  FIG. 4 ) is operable for positioning the saw  58  to a selected distance from the fence side rail  14  for performing the desired cut on the material being cut. Moveable push-locking mechanisms  74  are screwed down to secure the part being cut and will enable the user to guide the material through the saw without the risk of getting the users hands close to the saw blades. The push-lock mechanisms  74  also keep the part from being kicked back into the face of the user. 
       FIG. 8  illustrates the components within the pushlock mechanism  74 . The push-lock handle  76  is secured to one end of an adjustment screw  78 . The middle portion of the adjustment screw  78  is affixed to a threaded block  80  which travels up/down in accordance to the turning of the screw  78 . The bottom portion of the adjustment screw  78  is affixed to a bearing block  84 , which allows the adjustment screw  78  to turn freely and yet stayed secured to the block  84 . Block  84  also serves as linear bearing, which contains a composite surface on the bottom surface of the block  84  and allows the block to be secured but move laterally in conjunction with the rail  82  which is permanently attached to the work module top surface (see  FIG. 7 ). 
       FIG. 9  illustrates a plan view of the saw slide mechanism  64  depicted without the rolling deck  56  (see  FIG. 5 ). The saw slide mechanism includes; two elongated slide rods  86  positioned in a spaced parallel arrangement. Two saws  58  and  60  are attached to a base plate  88 . The base plate  88  contains four composite bearings (not shown) on all four corners of the base plate, which allow the saws to move horizontally on the slide rods  86 . Two pillow blocks  90  are provided to secure the ends of the guide rods  86  and the feed screw  92 . The feed screw  92  is Rota ably received into the pillow blocks  90 . The feed screw  92  extends between the pillow blocks with the feed screw thread ably engaging the saw base plate  88  whereby the saws are laterally positioned by the turning of the feed screw  92 . In a preferred embodiment the slide rods  86  are 1.5 inch in diameter and are chrome plated or stainless steel. The screw  92  is a 1.0 inch diameter and is a stainless steel screw with a 0.025 per/inch pitch threads. 
       FIG. 10  illustrates a side view of the dual slide module  94  with the right saw  60  in the raised ready for use position. This view of the saw slide module depicts a stepper actuator  96  operable for selectively vertical positioning of the saw  60  between a first lowered (stored) positions and a second raised ready for use position. The stepper actuator is provided with a limit switch  98  for sensing when the saw is in the retracted position. The guide roll  100  is a guide roller for the roller deck  66  (see  FIG. 5 ) and provides a movable surface for the roller deck to roll upon.  FIG. 10  does not depict the saw  58 , which has duplicate components (stepper actuator/actuator limit switch/guide roller) and is a mirror image of this illustration  FIG. 10 . 
       FIG. 11  illustrates the electrical controls for the saw slide module components. Inside (not shown) the drive panel  102  contains the drive for the stepper screw motor, solid state relays for the saw motors and a micro-logic controller that controls all the components which includes the safety interlocks needed to operate the saw module safely. The front face of the drive panel  102  includes; a main power LED indicating light  108 , a table top limit LED indicating light  110 , a saw retract limit LED indicating light  110 , a foot switch LED indicating light  112 , a main power on/off key switch  114 , a saw enable/disable selector switch  116 , a saw extend toggle switch  118 , a fast feed toggle switch  120  for selectively commanding the saws into the cut position, a slow feed toggle switch  122  for selectively commanding the saws into the cut position for small incremental moves of the saws, digital display  124  shows the position of the saw by displaying the current position in inches, the zeroing pushbutton  126  is fro re-zeroing the digital display to 0.00″ and can be implemented at any position of the saw slide. 
       FIG. 11  also depicts the ANSI approved hand held control pendant  104  which includes; a maintained emergency stop button  128  to disable all saw motion controls, a saw enable/disable selector switch  130  which disables the saw operation and must be used when positioning the saws in there extended position and therefore prohibit the accidental starting of the saws while trying to measure and position saws for use. The hand held pendant  104  also includes a saw extend selector switch  132  which raises the saws into there saw position and allows the user to properly align the saw slide module with the screw feed positioning with the use of fast feed toggle switch  134  or the slow feed toggle switch  136  which operates the feed screw to the desired position for the cut. The hand held pendant is electrically connected via a SOOW type pendant cable  138 . 
       FIG. 11  further depicts a saw start foot-switch  140  which is interfaced to the controls and prohibits the operation of the saws unless the switch is depressed. 
     This patent application was submitted with the concept of an optimum work module for the major contractor but this invention should be introduced as an optional package that can be an attractive incentive for even the casual user by selecting a model in accordance to their needs. This package could be offered with different variations of the pre-described components; saw slide module, saw dust bin, miter saw, router/drill, push-lock mechanism and the pre-wired module. 
     All illustrations and descriptions have been made to the accompanying drawings that form a part hereof, and in which are shown by the way of illustration specific embodiments in which the invention may be practiced. These embodiments and certain variants thereof have been described in sufficient detail to enable those skilled in the art to practice the invention. It is to be understood that other suitable embodiments may be utilized and that logical, material and mechanical changes may be made without departing from the spirit or scope of the invention. To avoid unnecessary detail, the description is, therefore, not intended to cover such alternatives.

Technology Category: 7