Patent Document

CROSS REFERENCE TO RELATED APPLICATIONS 
     Not Applicable 
     FEDERALLY SPONSORED RESEARCH 
     Not Applicable 
     SEQUENCE LISTING OR PROGRAM 
     Not Applicable 
     FIELD OF THE INVENTION 
     The present invention relates to a device that allows a user to cope cut a workpiece of varying dimensions at various diameters and angles without having to change the diameter of the cutting tool. 
     BACKGROUND OF THE INVENTION 
     When adjoining two pieces of pipe, dowel, or rod it is desired that the joint is smooth and conforms to the diameter of the material joined. Typically, the best way to join these materials is through a cope cut. In a cope cut, the end wall of a first material is cut to match the diameter of the side wall of the second material. Often when joining metal materials, this joint is welded. A cope cut is commonly used when constructing railings, racks, and guardrails out of pipe and tubing. 
     Traditionally, this cope cut is made with a band saw or other similar tool. According to this method, a user will draw or trace the curve to be cut and carefully use the saw to remove the material along this curve. This is time consuming and often requires additional cuts or grinds to ensure a precise fit. More recently, this type of cut has been prepared using a milling type machine with the cut made by a tool sized to the diameter of the pipe to be fit. This requires several tools with varying diameters to accommodate the varying diameters of pipe. Additionally these machines are often very large and require a dedicated electrical connection. Therefore, a device is needed to perform a cope cut that cuts varying diameters of pipe without changing the tool, is portable, and uses standard household electrical current. 
     SUMMARY OF THE INVENTION 
     A coping apparatus is provided that performs a cope cut on varying sizes and types of materials. The apparatus is able to make this cope cut of varying diameters and angles on multiple sizes of materials without having to change the cutting tool. To perform this cope cut, the cutting tool of the apparatus is moveable in an arc and moveable at an angle relative to the workpiece. To facilitate the cutting of a cope of multiple diameters without having to change the cutting tool, the radius of the cutting arc of the apparatus is adjustable. To facilitate the cutting of this cope at multiple angles the coping apparatus is pivotally moveable at an angle relative to the workpiece, wherein the user adjusts the angle of the cutting tool to correspond to the angle of the desired cope cut. 
     The coping apparatus includes a base. The base includes holes to allow a user to affix the base to a floor or a substrate. The base can be fastened to an existing concrete floor by using anchored or fixed bolts. In addition, the base can be fastened to a metal plate. In this configuration, the apparatus is moved to the work location where the base is temporarily affixed to a plate using a bolt or other similar fastener. 
     A riser is centrally mounted perpendicular to the base. The riser is designed to raise a workpiece off of the floor or substrate to create a more comfortable and safer working height for the user. A table is mounted perpendicular to the riser and opposite the base. The table has a first end, a second end, and a clamp. The clamp is adjustable in a vertical direction relative to the table to tightly secure the workpiece from movement during use of the apparatus. The clamp may include a knob to allow the user to easily adjust the tension applied to the workpiece. The table first end receives the workpiece. The table second end allows for the pivotal attachment of a housing. 
     The housing is cylindrical shaped and provides protection for the user of the apparatus. The housing includes a workpiece aperture. The workpiece aperture is aligned with the table second end and sized to receive the workpiece. The housing is pivotally attached to second end using two brackets. The brackets are mirror images of each other and fixed to the second end using a first fastener and fixed to the housing a second fastener. The brackets include a arcuate aperture allowing the housing to pivot at an angle from a range of 45° to 135° relative to the table. A third fastener extends through the arcuate aperture and into the housing. The third fastener is adjustable and applies frictional tension to the connection of the bracket and the housing, whereby adjustment of the third fastener will allow the user to pivot and secure the angle of the housing relative to the table. The location of the third fastener within the arcuate aperture will indicate the angle of the housing relative to the table. The bracket includes a first indicator to show the user the angle of the housing relative to the table. 
     A yoke assembly is in communication with the housing and allows a tool to move in an arc and move in a direction radial to this arc, wherein the radius of the arc is adjustable. The yoke assembly includes a upper disc, a lower disc, a upper arm, a lower arm, a connector, and a handle. The upper disc is cylindrical and sized to be rotatably received in the top of the housing, wherein the disc will seat in the housing and rotate through an arc. The upper disc includes a first channel and a second adjustment block adjacent to the first channel. The first channel is sized to tightly receive the upper arm. The first channel provides lateral support for the upper arm as the tool is moved through the workpiece. A first channel aperture is located central to the first channel to allow the tool to be received in the yoke upper arm. The first channel aperture is aligned with a lower aperture and allows the tool space to move within the housing. 
     The upper arm is slidably received in the first channel. The upper arm includes a first adjustment block and a stop aperture. The first adjustment block is fixed to the upper arm and in alignment with the second adjustment block. A rod connects the first adjustment block and the second adjustment block. The radius of the cutting arc of the tool is adjusted by pulling apart or pushing together the first adjustment block and the second adjustment block. In the preferred embodiment of the present invention, a threaded rod is used to adjust the distance between the first adjustment block and the second adjustment block. A threaded rod is preferred for its strength and multiple radii of adjustment, but other forms of adjustment may be used, such as a notched rod and securing pin. A second indicator is placed on the upper disc. The second indicator displays the diameter of the radius the apparatus will cope. This indicator will correspond to the outer diameter of the material to be joined by the cope cut. 
     The upper arm includes the stop aperture. The stop aperture is sized to correspond to the maximum and minimum cutting radius of the apparatus. A stop is fixed to the upper disc in stop aperture. The stop ensures that the tool remains in the working radii of the apparatus. 
     The upper arm contains a recess aligned with the first channel aperture. The recess includes a bearing. The tool extends the height of the housing and has a upper end with a diameter corresponding to the diameter of the recess. The tool upper end is received in the recess. The receipt of the tool upper end in the recess allows the tool to move along with the radial movement of the yoke assembly. Additionally, the receipt of the tool upper end in the recess provides added support for the tool from shearing forces as the tool is advanced through the workpiece. 
     The lower arm is connected to the upper arm by the connector. The lower arm is seated in a second channel of the lower disc. The lower disc is cylindrical and sized to be rotatably received in the bottom of the housing, wherein the disc will seat in the housing and rotate through an arc. The second channel is centrally located on the lower disc and is sized to tightly receive the lower arm. The second channel includes the lower disc aperture. The second channel aperture is located central to the second channel to allow the tool entry to the interior of the housing. The second channel aperture is aligned with the channel aperture and allows the tool space to move within the housing as the radius of the cutting arc is adjusted. 
     The handle extends outward from the connector and opposite the housing allowing a user to rotate the yoke assembly within the housing and engage the tool in the workpiece. The yoke assembly moves the tool within an arc as the user manipulates the handle by pulling or pushing. The yoke assembly will swing through an arc of 114° from a position parallel to the table and a through a total arc of 228°. 
     A motor bracket is mounted to the lower arm seated in the second channel of the lower disc. A motor is connected to the motor bracket. The motor is fixed to the motor bracket using a fourth fastener. The motor turns a spindle. The tool is removably fixed to the spindle. The tool extends the height of the housing and is in communication with the upper arm. The connection of the motor to the motor bracket allows the motor to move with the yoke assembly as the yoke assembly is rotated through its arc and into the workpiece. The motor is an electric fixed speed motor that operates on a standard household current of 120 volts. The tool is composed of cutting teeth to remove material from the workpiece as the tool is engaged in the workpiece. The tool is preferably a modified milling cutter with a diameter of one inch (1 in.). The tool may be a left cutting mill or right cutting mill 
     A tool aperture is located through the motor bracket and the lower arm. The tool aperture is aligned with the second channel aperture and allows the tool affixed to the spindle access to the interior of the housing. A lower stop aperture through the motor bracket and lower arm is sized to correspond to the cutting radius of the device. A second stop is received in the lower stop aperture and affixed to the lower disc. The second stop secures the lower arm and motor bracket to the disc and allows the motor and tool to rotate with the discs and move with the yoke. In the preferred embodiment of the present invention, the motor bracket is fixed to the lower arm using a removable fastener. 
     The workpiece is secured to the table using the clamp. The clamp is adjustable by tightening or loosening the knob. The table may contain a second clamp and second knob to aid in securing the workpiece. When two clamps are used, a clamp bridge may be used to further secure the workpiece to the table. Preferably the clamp bridge is constructed out of angle iron to accommodate pipe or tubing or varying diameters. 
     To make a 90° cope cut, a user will first secure the workpiece to the table using the clamp. The user will then use the first indicator to ensure that the housing is positioned perpendicular to the work piece at an angle of 90°. The user will then turn on the motor to begin the rotation of the tool. The user will then push or pull the handle in an arc moving the yoke assembly and engaging the tool in the workpiece. 
     To make an angular cope cut, a user will first secure the workpiece to the table using the clamp. The user will then loosen the third fastener and pivot the housing to the desired angle between a range of 45° to 135° relative to the table. The user will then tighten the third fastener and confirm the cutting angle using the first indicator. The user will then turn on the motor to begin the rotation of the tool. The user will then push or pull the handle in an arc moving the yoke assembly and engaging the tool in the workpiece. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
       The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the present invention and together with the description serve to further explain the principles of the invention. Other aspects of the invention and the advantages of the invention will be better appreciated as they become better understood by reference to the Detailed Description when considered in conjunction with accompanying drawings, and wherein: 
         FIG. 1  is a perspective view of apparatus, according to the present invention; 
         FIG. 1A  is a perspective view of an alternate embodiment of the apparatus, according to the present invention; 
         FIG. 2  is a top view of the apparatus with the upper disc  511  removed, according to the present invention; 
         FIG. 3  is a perspective view of joined pipe sections using a 90 degree cope cut, according to the present invention; 
         FIG. 4  is a close-up view of the alignment markings on the pivoting bracket of the apparatus, according to the present invention; 
         FIG. 5  is a sectional view of the apparatus as shown in  FIG. 6  taken at the sectioning plane and in the direction indicated by section line  5 - 5 , according to the present invention; 
         FIG. 6  is a side view of the apparatus with the housing pivoted to cut a 45 degree cope, according to the present invention; 
         FIG. 7  is a perspective view of joined pipe sections using a 45 degree cope cut, according to the present invention; 
         FIG. 8  is a top view of the housing and yoke, according to the present invention; 
         FIG. 9  is cross-sectional view of the housing in  FIG. 8  taken at the sectioning plane and in the direction indicated by the section line  9 - 9 , according to the present invention; 
         FIG. 10  is a bottom view of the device in  FIG. 1  taken at the sectioning plane in the direction indicated by the section line  10 - 10 , according to the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Referring now to  FIG. 1  there is shown an embodiment of the coping apparatus of the present invention, generally designated by the reference numeral  10 . Coping apparatus  10  includes a base  100 . Base  100  includes holes  101  to allow a user to affix the base to a floor or a substrate. The base  100  can be fastened to an existing concrete floor by using anchored or fixed bolts. In addition, the base  100  can be fastened to a metal plate. In this configuration, the apparatus  10  is moved to the work location where the base is temporarily affixed to a plate using a bolt or other similar fastener. 
     A riser  200  is centrally mounted perpendicular to the base  100 . The riser  200  is designed to raise a workpiece  20  off of the floor or substrate to create a more comfortable and safer working height for the user. A table  300  is mounted to perpendicular to the riser  200  and opposite the base  100 . The table  300  has a first end  303 , second end  304 , and a clamp  301 . The clamp  301  is adjustable in the vertical direction relative to the table  300  to tightly secure the workpiece  20  from movement during use of the apparatus  10 . The clamp  301  may include a knob  302  to allow the user to easily adjust the tension applied to the workpiece  20 . The first end  303  receives the workpiece  20 . The second end  304  allows for the pivotal attachment of a housing  400 . 
     The housing  400  is cylindrical shaped and provides protection for the user of the apparatus  10 . The housing  400  includes a workpiece aperture  407 . The workpiece aperture  407  is aligned with the table second end  304  and sized to receive the workpiece  20 . The housing  400  is pivotally attached to second end  304  using two brackets  401 . Brackets  401  are mirror images of each other and fixed to the second end  304  using a first fastener  403  (seen in  FIG. 6 ) and fixed to the housing a second fastener  404  (seen in  FIG. 6 ). The bracket  401  includes a arcuate aperture  405  allowing housing  400  to pivot from a range of 45° to 135° relative to the table  300 . A third fastener  402  extends through the arcuate aperture  405  and into the housing  400 . The manipulation of the third fastener  402  allows the user to adjust the angle of the housing  400 . A tightening of the third fastener  402  will secure the housing at the desired angle while a loosening of the fastener  402  will allow the user to pivot the housing  400  to the desired angle. The bracket  401  includes a first indicator  406  to show the user the angle of the housing  400 , as shown in  FIG. 4 . 
     A yoke assembly  500  is in communication with the housing  400  and allows a tool  700  to move in an arc and move in a direction radial to this arc, wherein the radius of the arc is adjustable. The yoke assembly includes a upper disc  511 , a lower disc  519 , a upper arm  501 , a lower arm  502 , a connector  518 , and a handle  503 . The upper disc  511  is cylindrical and sized to be rotatably received in the top of the housing  400 , wherein the upper disc  511  will seat in the housing  400  and rotate through an arc. The upper disc  511  includes a first channel  512  and a second adjustment block  515  adjacent to the first channel  512 . 
     The upper arm  501  is slidably received in the first channel  512 . The upper arm includes a first adjustment block  504  and a stop aperture  516  (shown in  FIG. 8 ). The first adjustment block  504  is fixed to the upper arm  501  and in alignment with the second adjustment block  515 . A rod  508  (as shown in  FIG. 8 ) connects the first adjustment block  504  and the second adjustment block  515 . Manipulation of the rod  508  will slidably move the upper arm  501  within the first channel  512  thereby moving the yoke assembly  500  and the tool  700  in a direction radial to the rotation of the upper disc  511  and the lower disc  519  within the housing  400 . In the preferred embodiment of the present invention, the rod  508  is a threaded rod. 
     The lower arm  502  is connected to the upper arm by the connector  518 . The lower arm  502  is seated in a second channel  520  ( FIG. 10 ) of the lower disc  519 . The lower disc  519  is cylindrical and sized to be rotatably received in the bottom of the housing  400 , wherein the disc will seat in the housing  400  and rotate through an arc. A motor bracket  506  is fixed to the lower arm  502  and lower disc  519 . The handle  503  extends outward from the connector  518  opposite the housing  400 . The handle  503  allows the user to push or pull the yoke assembly  500  through an arc engaging the tool  700  in the workpiece  20 . 
     A motor  600  is connected to the motor bracket  506 . The connection of the motor  600  to the motor bracket  506  allows the motor  600  to move with the yoke assembly  500 . The motor  600  is an electric fixed speed motor that operates on a standard household current of 120 volts. The tool  700  is rotated by a connection to the motor  600  and is composed of cutting teeth to remove material from the workpiece  20  as the tool  700  is engaged in the workpiece  20 . The tool  700  extends the length of the housing  400 . The tool  700  is preferably a modified milling cutter with a diameter of one inch (1 in.). The tool  700  may be a left cutting mill or right cutting mill. 
     Referring now to  FIG. 1A , a perspective view of an alternate embodiment of the present invention, there is shown motor  600 . The motor  600  is mounted to the motor bracket  506  and positioned parallel to the handle  503 . To facilitate proper rotation of the tool  700 , a gearbox  602  is required. The gearbox  602  is in communication with a spindle (not pictured) rotated by the motor  600  and translates this rotation to the tool  700  via intermeshed gears (not pictured). This pictured embodiment does not alter the working mechanics or functionality of the apparatus  10 . 
     Referring now to  FIG. 2 , a top view of the apparatus with the upper disc  511  removed, there is shown the workpiece  20  engaged by the tool  700 . Workpiece  20  is secured to the table  300  using the clamp  301 . The clamp  301  is adjustable by tightening or loosening the knob  302 . The table  300  may include two clamps  301  to ensure that the workpiece  20  is tightly secured to the table  300 . When two clamps  301  are used, a clamp bridge  307  may be used to further secure the workpiece  20  to the table  300 . Preferably the clamp bridge  307  is constructed out of angle iron to accommodate pipe or tubing or varying diameters. 
     The housing  400  is pivotally secured to the table second end  304  using the bracket  401 . The bracket  401  includes a first indicator  406  (seen in  FIG. 4 ) to show the angle of the housing  400  relative to the table  300  as the housing  400  is pivotally moved. 
     A tool aperture  505  is present in the lower disc  519 . The tool aperture  505  is aligned with the tool  700  and shaped to accommodate the movement of the tool  700  within the housing  400 . The yoke upper arm  501  is in communication with the handle  503 . The handle  503  extends outward from the yoke assembly  500  (seen in  FIG. 1 ) opposite the housing  400  and allows a user to rotate the yoke assembly  500  within the housing  400  and engage the tool  700  in the workpiece  20 . The yoke assembly  500  moves the tool  700  within an arc as the user manipulates the handle  503  by pulling or pushing. The yoke assembly  500  will swing through an arc of 114° from a position parallel to the table  300  and a through a total arc of 228°. 
     To make a 90° cope cut, as shown in  FIG. 3 , a user will first secure the workpiece  20  to the table  300  using the clamp  301 . The user will then use the first indicator  406  (seen in  FIG. 4 ) to ensure that the housing  400  is positioned perpendicular to the workpiece  20  at an angle of 90°. The user will then turn on the motor  600  to begin the rotation of the tool  700 . The user will then push or pull the handle  503  in an arc moving the yoke assembly  500  and engaging the tool  700  in the workpiece  20 . 
     Referring now to  FIG. 6 , a side view of the apparatus with the housing  400  pivoted to cut a 45° cope as shown in  FIG. 7 . The table  300  is connected perpendicular to the riser  200 . The first end  303 , the second end  304 , the clamp  301 , a second clamp  306 , the knob  302 , and a second knob  305  are shown. The clamp  301  and the second clamp  306  secure the workpiece  20  to the table  300 . The housing  400  is mounted to the table  300  by the bracket  401 . The bracket  401  is mounted to the table  300  using the first fastener  403 . In the preferred embodiment of the present invention, the first fastener  403  is a threaded bolt. The bracket  401  includes the arcuate aperture  405 . The third fastener  402  extends through the arcuate aperture  405  and is secured to the housing  400 . The third fastener  402  is adjustable and applies frictional tension to the connection of the bracket  401  and the housing  400 , whereby adjustment of the third fastener  402  will allow the user to secure the angle of the housing  400  relative to the table  300 . The location of the third fastener  402  within the arcuate aperture  405  will correspond to the angle of the housing  400  relative to the table  300  and be displayed on the first indicator  406 , as shown in  FIG. 5 . 
     The motor bracket  506  is mounted to the lower arm  502  seated in the second channel  520  of the lower disc  519 . The motor  600  is fixed to the motor bracket  506  using fourth fastener  509 . The motor  600  turns a spindle  601 . The tool  700  is removably affixed to the spindle  601 . The connection of the motor  600  to the motor bracket  506  allows the motor  600  to move with the yoke assembly  500  as the yoke assembly  500  is rotated through its arc and into the workpiece  20 . 
     To make a 45° cope cut, as shown in  FIG. 7 , a user will first secure the workpiece  20  to the table  300  using the clamp  301 . The user will then use the first indicator  406  (seen in  FIG. 4 ) to ensure that the housing  400  is positioned at a 45° angle relative to the workpiece  20 . To pivot the housing  400 , the user will loosen the third fastener  402  and pivot the housing  400  to the proper angle. The user will then turn on the motor  600  to begin the rotation of the tool  700 . The user will then push or pull the handle  503  in an arc moving the yoke assembly  500  and engaging the tool  700  in the workpiece  20 . 
     Referring now to  FIG. 8 , a top view of the housing  400  and yoke assembly  500 , according to the present invention there is shown the housing  400  and the upper disc  511 . The upper disc  511  is rotatably received within the housing  400 . The upper disc  511  includes the first channel  512 . The first channel  512  is sized to tightly receive the upper yoke arm  501 . The first channel  512  provides lateral support for the upper yoke arm  501  as the tool  700  is moved through the workpiece  20 . A first channel aperture  513  is located central to the first channel  512  to allow the tool  700  to be received in the yoke upper arm  501 . The first channel aperture  513  is aligned with the second channel aperture  521  (seen in  FIG. 2 ) and allows the tool  700  space to move. 
     The radius of the tool cutting arc is adjustable by moving the upper yoke arm  501  within the first channel  512 . The first adjustment block  504  is fixed to the yoke upper arm  501  and the second adjustment block  515  is fixed to the upper disc  511 . The radius of the cutting arc of the tool is adjusted by pulling apart or pushing together the first adjustment block  504  and the second adjustment block  515 . In the preferred embodiment of the present invention, a threaded rod  508  is used to adjust the distance between the first adjustment block  504  and the second adjustment block  515 . A threaded rod is preferred for its strength and multiple radii of adjustment, but other forms of adjustment may be used, such as a notched rod and securing pin. A second indicator  510  is placed on the upper disc  511 . The second indicator  510  displays the diameter of the radius the apparatus will cope. This second indicator  510  will correspond to the outer diameter of the material to be joined by the cope cut. 
     The upper arm  501  includes the stop aperture  516 . The stop aperture  516  is sized to correspond to the maximum and minimum cutting radius of the apparatus. The stop  514  is fixed to the upper disc  511  in the stop aperture  516 . The stop  514  ensures the tool  700  remains in the working radii of the apparatus. 
     Referring now to  FIG. 9 , a cross-section view of the housing and yoke assembly along plane  9 - 9  in  FIG. 8 , there is shown the housing  400  and the upper disc  511 . The upper disc  511  is rotatably received in the housing  400 . The yoke upper arm  501  is fixed to the upper disc  511  by the connection of the first adjustment block  504  to the second adjustment block  515  using the threaded rod  508 . Adjustment of the threaded rod  508  will adjust the radius of the arc of the cut. The stop  514  will prevent the tool  700  from exceeding its upper or lower cutting limits. The upper arm contains a recess  507  aligned with the first channel aperture  513 . The recess  507  includes a bearing  517 . The tool  700  has a upper end  701  with a diameter corresponding to the diameter of recess  507 . The tool upper end  701  is received in the recess  507 . The receipt of tool upper end  701  in the recess  507  allows the tool  700  to move along with the radial movement of the upper arm  501 . Additionally, the receipt of the tool upper end  701  in the recess  507  provides added support for the tool from shearing forces as the tool  700  is advanced through the workpiece  20 . 
     Referring now to  FIG. 10 , a bottom view of the device in  FIG. 1  taken at the sectioning plane in the direction indicated by the section line  10 - 10 , there is shown the housing  400  and the lower disc  519 . The lower disc  519  is rotatably received within the housing  400  and includes the second channel  520 . The second channel  520  is centrally located on the lower disc  519  and is sized to tightly receive the lower arm  502 . The second channel  520  includes the second channel aperture  521 . The second channel aperture  521  is located central to the second channel  520  to allow the tool  700  entry to the interior of the housing  400 . The second channel aperture  521  is aligned with the first channel aperture  513  (seen in  FIG. 8 ) and allows the tool  700  space to move within the housing  400 . 
     The motor bracket  506  is fixed to the lower arm  502 . A tool aperture  505  is located through the motor bracket  506  and lower arm  502 . The tool aperture  505  is aligned with the second channel aperture  521  and allows the tool  700  affixed to the spindle  601  access to the interior of the housing  400 . A lower stop aperture  524  through the motor bracket  506  and lower arm  502  is sized to correspond to the cutting radius of the device. A second stop  523  is received in the lower stop aperture  524  and affixed to the lower disc  519 . The second stop  523  secures the lower arm  502  and motor bracket  506  to the disc  519  and allows the motor  600  and tool  700  to rotate with the discs and move with the yoke. In the preferred embodiment of the present invention, the motor bracket  506  is fixed to the lower arm  502  using a removable fastener  522 .

Technology Category: 4