Patent Document

BACKGROUND 
       [0001]    1. Field of the Invention 
         [0002]    The present invention generally relates to power tools and particularly to power hand tools having a cutting guide. 
         [0003]    2. Related Art 
         [0004]    Power hand tools such as miter saws, circular saws, as well as other hand tools are often provided with the capability of adjusting the depth of cut or the bevel angle. Where such adjustability is provided in a tool, there is generally a measurement display or indicator present on the tool that will enable the user to set the angle or depth of cut at the desired location that is substrate independent. 
       INTRODUCTION TO THE INVENTION 
       [0005]    It is a first aspect of the present invention to provide a cutting guide for a saw, the guide comprising: (a) a guide including a follower path, the guide including a plurality of indicia each representative of a plurality of different substrates; (b) a follower repositionable with respect to the guide along the follower path and into alignment with at least one of the plurality of indicia; and, (c) a lock operatively coupled to the follower, the lock being repositionable between a locked position and an unlocked position, the locked position operative to retain the guide in a fixed position with respect to the follower, and the unlocked position operative to allow a relative position of the guide with respect to the follower to be changed. 
         [0006]    In a more detailed embodiment of the first aspect, the guide comprises an arcuate loop that defines the follower path, the follower path is partially defined by a through opening having a substantially constant radius of curvature, and a plurality of indicia are spaced apart from one another along a length of the arcuate loop. In yet another more detailed embodiment, the follower includes an arcuate segment, and the plurality of indicia comprise spaced apart arcuate markings that each approximate an arc of the arcuate segment. In a further detailed embodiment, the plurality of indicia include a plurality of numerical identifiers that are substrate specific. In still a further detailed embodiment, the plurality of indicia represent at least one of the same material with differing thicknesses and different materials. In a more detailed embodiment, the guide is repositionable with respect to the follower, the follower has a fixed position, and the lock in the locked position is operative to form a wedge in between the guide and follower to retain the guide in the fixed position with respect to the follower. 
         [0007]    It is a second aspect of the present invention to provide a power saw comprising: (a) a motor coupled to a motor housing, the motor housing including a handle and a trigger; (b) a base plate repositionably mounted to the motor housing; (c) a guide coupled to the base plate, the guide defining a follower path, the guide including a plurality of indicia each representative of a plurality of different substrates; (d) a follower coupled to at least one of the motor and motor housing, the follower repositionable with respect to the guide along the follower path and into alignment with at least one of the plurality of indicia; and, (e) a lock operatively coupled to the follower, the lock being repositionable between a locked position and an unlocked position, the locked position operative to retain the guide in a fixed position with respect to the follower, and the unlocked position operative to allow a relative position of the guide with respect to the follower to be changed. 
         [0008]    In a more detailed embodiment of the second aspect, the guide comprises an arcuate loop that defines the follower path, the follower path is partially defined by a through opening having a substantially constant radius of curvature, and a plurality of indicia are spaced apart from one another along a length of the arcuate loop. In yet another more detailed embodiment, the follower includes an arcuate segment, and the plurality of indicia comprise spaced apart arcuate markings that each approximate an arc of the arcuate segment. In a further detailed embodiment, the plurality of indicia include a plurality of numerical identifiers that are substrate specific. In still a further detailed embodiment, the plurality of indicia represent at least one of the same material with differing thicknesses and different materials. In a more detailed embodiment, the guide is repositionable with respect to the follower, the follower has a fixed position, and the lock in the locked position is operative to form a wedge in between the guide and follower to retain the guide in the fixed position with respect to the follower. 
         [0009]    It is a third aspect of the present invention to provide a power saw comprising: (a) a motor coupled to a motor housing, the motor housing including a handle and a trigger; (b) a base plate repositionably mounted to the motor housing; (c) a guide coupled to at least one of the motor and motor housing, the guide defining a follower path, the guide including a plurality of indicia each representative of a plurality of different substrates; (d) a follower coupled to the base plate, the follower repositionable with respect to the guide along the follower path and into alignment with at least one of the plurality of indicia; and, (e) a lock operatively coupled to the follower, the lock being repositionable between a locked position and an unlocked position, the locked position operative to retain the follower in a fixed position with respect to the guide, and the unlocked position operative to allow a relative position of the follower with respect to the guide to be changed. 
         [0010]    In a more detailed embodiment of the third aspect, the guide comprises an arcuate loop that defines the follower path, the follower path is partially defined by a through opening having a substantially constant radius of curvature, and a plurality of indicia are spaced apart from one another along a length of the arcuate loop. In yet another more detailed embodiment, at least one of the lock and the follower includes an arcuate segment, and the plurality of indicia comprise spaced apart arcuate markings that each approximate an arc of the arcuate segment. In a further detailed embodiment, the plurality of indicia include a plurality of numerical identifiers that are substrate specific. In still a further detailed embodiment, the plurality of indicia represent at least one of the same material with differing thicknesses and different materials. In a more detailed embodiment, the follower is repositionable with respect to the guide, the guide has a fixed position, and the lock in the locked position is operative to form a wedge in between the guide and follower to retain the follower in the fixed position with respect to the guide. 
         [0011]    It is a fourth aspect of the present invention to provide a method of providing a cutting guide for a power saw, the method comprising: (a) providing a guide that includes a plurality of substrate-specific indicia representative of a plurality of different substrates that may be cut by the power saw; and, (b) providing a follower that is relatively repositionable with respect to the guide to notify a user when the power saw is properly configured to cut through one of the plurality of different substrates when the follower is aligned with at least one of the plurality of substrate-specific indicia. 
         [0012]    In a more detailed embodiment of the fourth aspect, the method further includes the act of providing a lock to fix the relative positions of the follower with respect to the guide to maintain the proper configuration of the power saw. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0013]      FIG. 1  is an elevated perspective view from the rear, left side of a circular saw incorporating the exemplary cutting guide in accordance with the present invention; 
           [0014]      FIG. 2  is an elevated perspective view from the rear, right side of the circular saw of  FIG. 1 ; 
           [0015]      FIG. 3  is an elevated perspective view of an exemplary guide for use with the circular saw of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    The exemplary embodiments of the present disclosure are described and illustrated below to encompass guides for cutting saws and methods of guiding a user of a cutting saw to ensure the cutting saw is properly configured. Of course, it will be apparent to those of ordinary skill in the art that the embodiments discussed below are exemplary in nature and may be reconfigured without departing from the scope and spirit of the present disclosure. However, for clarity and precision, the exemplary embodiments as discussed below may include optional steps, methods, and features that one of ordinary skill should recognize as not being a requisite to fall within the scope of the present disclosure. 
         [0017]    Referencing  FIGS. 1 and 2 , an exemplary circular saw  8  is illustrated and generally shows a cutting guide  10  and a bevel guide  12 . Both guides  10 ,  12  are implemented in exemplary form with a circular saw  8  having a motor housing  14 , a handle  16 , an auxiliary handle  18 , a foot  20 , as well as a blade housing  22  in which a saw blade is located. 
         [0018]    The saw  8  may be adjusted to ensure the saw is properly configured to completely cut through one of a plurality of different substrates. As used herein, substrate refers to any physical medium that may be severed by a saw. By way of example, and not limitation, a piece of wood having dimensions of 1.5 inches by 3.5 inches by some length dimension (commonly known as a 2×4) would be substrate, while another piece of wood having dimensions of 1.5 inches by 5.5 inches by some length dimension (commonly known as a 2×6) would be different substrate even though both substrates are fabricated from the same material. Likewise, different substrates may have the same dimensions but be fabricated from different materials (e.g., wood vs. wood &amp; glue or wood vs. stone). 
         [0019]    In order to properly configure the saw, a user may utilize the cutting guide  10 . This cutting guide  10  allows the saw blade (not shown), the saw blade housing  22 , and the motor housing  14  to pivot around an axis defined by a bolt  24 . A lock  26  is coupled to the handle  16  and rides within an arcuate slot  28  provided in a generally arcuate bracket  30  that is mounted to the motor housing  14  by bolts, screws, or other structure known to those of ordinary skill in the art. 
         [0020]    Similarly, the angle of the saw blade can be adjusted by using bevel guide  12 . The bevel guide  12  includes a bevel bracket  32  that may be integrally formed with the foot structure  20 . The saw blade housing  22 , which is mounted to the motor housing  14 , is operative to change its orientation with respect to the foot structure  20  by way of pivoting around an axis defined by a bolt  34 . An arcuate slot  36  within the bevel bracket  32  is configured to have a constant radius of curvature with respect to the bolt  34  and a locking lever  38  enables the bevel angle to be locked in place after a user has set the proper bevel angle. 
         [0021]    Turning now to  FIGS. 1-3 , concerning the cutting guide  10 , the bracket  30  includes a number of arcuate markings  40  along the longitudinal length of the bracket. These longitudinal markings correspond to the position of the saw blade operative to completely cut through different substrates. For instance, in exemplary form, the arcuate markings  40  are provided in a set of four paired markings. The first paired markings  40 A denote the position of the blade operative to cut completely through two inch lumber. In exemplary form, this first paired markings  40 A include a numerical identifier “2X”, indicating that blade is set to cut two inch lumber. The second paired markings  40 B denote the position of the blade operative to cut completely through three-quarter inch plywood or one inch lumber. In exemplary form, this second paired markings  40 B include two numerical identifiers “¾” and “1X”, indicating that blade is set to cut three quarter inch plywood or one inch lumber. The third paired markings  40 C denote the position of the blade operative to cut completely through one-half inch plywood. In exemplary form, this third paired markings  40 C include a numerical identifier “½”, indicating that blade is set to cut one-half inch plywood. The fourth paired markings  40 D denote the position of the blade operative to cut completely through one-quarter inch plywood. In exemplary form, this fourth paired markings  40 D include a numerical identifier “¼”, indicating that blade is set to cut one-quarter inch plywood. It should be noted that the markings to not numerically represent an actual depth of the blade, such as in prior art guides, but rather provide markings that confirm the blade is positioned to cut completely through the material with a predetermined undercut. In other words, the guide represents a numerical figure comprises of the depth of the material to be cut in addition to a predetermined undercut value (a depth of the blade that goes beyond (underneath) the substrate to be cut). And it should also be noted that any form of indicia may be used to indicate the position of the guide that is operative to cut through a particular substrate. 
         [0022]    Referring back to  FIGS. 1 and 2 , the locking lever  26  includes a lever handle  42  and a bolt  44  (i.e., threaded stud, carriage bolt or the like) that extends through the lever handle and into a threaded cavity of the motor housing  14 . In this manner, the lever handle  42  is pivotable around the bolt  44 , which extends through the arcuate bracket  30  and into engagement with the motor housing  14 . 
         [0023]    Referencing  FIGS. 1-3 , each set of markings  40  includes the same arc as the circumferential arc  46  of the lever handle  42 . As a result, when the lever handle  42  is positioned so that a pair of arcuate markings  40  are just outside of the portion of the lever handle with the circumferential arc  46 , the user of the saw knows that the position of the saw blade is configured to cut through the particular material denoted on the marking. But the lock  26  must be secured to maintain the position of the saw blade with respect to the foot  20 . 
         [0024]    Rotation of the lever handle  42  in the clockwise direction effects rotation of the bolt  44  in the same direction, thereby forming a wedge operative to clamp the bracket  30  between the lever handle and the motor housing to the blade housing  22 . This wedge is operative to fix the relative positions of the motor housing  14  and the blade housing  22  with respect to the foot  20 . Conversely, when the lever handle  42  is moved in a counterclockwise direction, the bolt  44  also turns in a counterclockwise direction, thereby discontinuing the clamp. Once the clamp is discontinued and a sufficient gap exists, the motor housing  14  and the blade housing  22  may be repositioned with respect to the foot  20  to change the position of the blade. 
         [0025]    Thus, in summary, the arcuate bracket  30  is mounted to the foot  20  and is configured so that the locking lever mechanism  26  may engage and reciprocate within the slot  28  disposed within the bracket. In exemplary form, the arcuate bracket  30  includes an elongated through hole that receives the bolt  44 . The arcuate profile of this through hole provides a constant radius of curvature to match the pivoting action of the foot  20  with respect to the motor housing  14 . In this exemplary embodiment, the arcuate bracket  30  is vertically and horizontally repositionable with respect to the bolt  44  as a result of the pivoting action of the foot  20  with respect to the motor housing  14 . Because the bolt  44  is rotationally repositionable, but not vertically or horizontally repositionable, one can consider the bolt to have a fixed position relative to the motor housing  14 , while the arcuate guide has a variable position with respect to the motor housing. 
         [0026]    In contrast to the foregoing explanation and depiction shown in  FIGS. 1 and 2 , it is also within the scope of the invention to switch the bolt  44  and arcuate bracket  30  so that the arcuate bracket is fixed in position, while the bolt has a variable position. In exemplary form, the arcuate bracket  30  is mounted to the motor housing  14 , while the bolt  44  is mounted to the foot  20 . In this manner, the bolt  44  is vertically and horizontally repositionable to ride within the through opening. 
         [0027]    Turning now to the bevel guide  12 , the bevel bracket  32  has the slot  36  as previously described through which a threaded fastener  50  (i.e., a carriage bolt, stud or the like) extends. The threaded fastener  50  also extends through an opening in a repositionable bevel handle  52  on one side of the bevel bracket  32 , while at the same time the threaded fastener extends into a cavity of a mounting bracket  54  coupled to the saw blade housing  22 . In this manner, the bevel handle  52  is pivotable around the threaded fastener  50 . And rotation of the bevel handle  52  in the clockwise direction as illustrated in  FIG. 1  effects rotation of the foot  20  and bevel bracket  32  with respect to the motor housing  14 , the blade housing  22 , and the mounting bracket  54 , thereby clamping the bracket  32  between the bevel handle and the bevel bracket. This clamping is operative to fix the relative positions of the foot  20  and bevel bracket  32  with respect to the motor housing  14 , the blade housing  22 , and the mounting bracket  54 . Conversely, when the bevel handle  52  is moved in a counterclockwise direction with reference to  FIG. 1 , the threaded fastener  50  also turns in a counterclockwise direction, thereby discontinuing the clamp. Once the clamp is discontinued and a sufficient gap exists, the foot  20  and bevel bracket  32  may be repositioned with respect to the motor housing  14 , the blade housing  22 , and the mounting bracket  54  to vary the bevel angle of cut of the blade. Thus, in summary, the bevel bracket  32  is mounted to the foot  20  and is configured so that the threaded fastener  50  may engage and reciprocate within the slot  36  disposed within the bracket. 
         [0028]    The bevel bracket  32  includes a number of markings  60  along the longitudinal length of the bracket. These longitudinal markings correspond to the angle of the saw blade with respect to the foot  20 . For instance, in exemplary form, the markings  60  are provided in nineteen paired markings. Each paired marking  60  denotes the angular position of the blade with respect to the foot  20  using five degree increments. 
         [0029]    For example, the first paired marking  60  denotes a zero degree beveled angle between the saw blade and the foot  20 , while the nineteenth paired marking denotes a ninety degree beveled angle between the saw blade and the foot. As a result, when the bevel handle  52  is positioned so that a pair of markings  60  are aligned with pointer  56  of the mounting bracket  54 , the user it provided with a guide indicating the angle at which the blade is oriented with respect to the foot  20 , which also corresponds to the angle at which the blade is oriented with respect to a planar substrate (adjacent and flat against the foot  20 ) to be cut. 
         [0030]    Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatuses herein described constitute exemplary embodiments of the present invention, the invention is not limited to the foregoing and changes may be made to such embodiments without departing from the scope of the invention as defined by the claims. Additionally, it is to be understood that the invention is defined by the claims and it is not intended that any limitations or elements describing the exemplary embodiments set forth herein are to be incorporated into the interpretation of any claim element unless such limitation or element is explicitly stated. Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of any claims, since the invention is defined by the claims and since inherent and/or unforeseen advantages of the present invention may exist even though they may not have been explicitly discussed herein.

Technology Category: 7