BEVEL SAWS CONFIGURED TO MAKE A BEVEL CUT IN A WORKPIECE

FIELD OF THE DISCLOSURE

The present disclosure is directed generally to bevel saws configured to make a bevel cut in a workpiece.

BACKGROUND OF THE DISCLOSURE

Bevel saws may be utilized to make a bevel, or angled, cut in a workpiece. Conventional bevel saws include a conventional bevel guide, which permits a bevel angle of the bevel cut to be selectively varied. In many conventional bevel saws, a cut location at which a circular saw blade of the bevel saw enters the workpiece varies, relative to a remainder of the bevel saw, with the bevel angle. As such, any cut guide of such a conventional bevel saw only may accurately represent the cut location for a single bevel angle and/or the bevel saw may include a plurality of cut guides, each referenced for a given bevel angle. While effective for imprecise cuts, such conventional bevel saws make it difficult to accurately cut the workpiece at a variety of different bevel angles. Thus, there exists a need for improved bevel saws configured to make a bevel cut in a workpiece.

SUMMARY OF THE DISCLOSURE

Bevel saws configured to make a bevel cut in a workpiece are disclosed herein. The bevel saws include a motor including a motor shaft configured to rotate about a shaft rotational axis. The bevel saws also include an arbor configured to operatively attach a circular saw blade to the bevel saws and/or to rotate the circular saw blade within a blade plane and/or about an arbor rotational axis when the arbor receives a torque from the motor via rotation of the motor shaft about the shaft rotational axis. The bevel saws further include a base plate that defines an arbor-facing side and an arbor-opposed side. The arbor is operatively attached to the arbor-facing side of the base plate such that the arbor-facing side of the base plate faces toward the arbor. The bevel saws also include a bevel guide, which is configured to selectively vary a bevel angle between the blade plane and the arbor-opposed side of the base plate within a bevel cut angular range-of-motion, such as to selectively vary an angle of the bevel cut within the workpiece.

In some examples, the bevel guide includes a guide plate that includes a first circular arc-shaped slot and a second circular arc-shaped slot. The first circular arc-shaped slot has a first radius of curvature that extends from a first origin. The second circular arc-shaped slot has a second radius of curvature that extends from a second origin that is spaced apart from the first origin.

In some examples, the bevel saws include a bevel guide mount configured to operatively attach the bevel guide to the base plate. The bevel guide mount includes a single bevel guide mount fastener that operatively attaches the bevel guide to the base plate. The bevel guide mount also includes a reinforcing structure that defines an opening. The bevel guide mount fastener extends through the opening such that the bevel guide is compressed between the reinforcing structure and the base plate. The bevel guide mount fastener includes a bevel guide mount fastener head that defines a fastener head transverse cross-sectional area, and a contact area between the reinforcing structure and the bevel guide is at least 10 times the fastener head transverse cross-sectional area.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic front view illustrating examples of bevel saws, according to the present disclosure, illustrating a first bevel angle.

FIG. 2 is another schematic front view of the bevel saws of FIG. 1 illustrating a second bevel angle.

FIG. 3 is a schematic side view of the bevel saws of FIGS. 1-2.

FIG. 4 is a less schematic top profile view of an example of a bevel saw according to the present disclosure.

FIG. 5 is a less schematic right side view of an example of a bevel saw according to the present disclosure.

FIG. 6 is a less schematic left side view of an example of a bevel saw according to the present disclosure.

FIG. 7 is another less schematic left side view of an example of a bevel saw according to the present disclosure.

FIG. 8 is another less schematic left side view of an example of a bevel saw according to the present disclosure.

FIG. 9 is a less schematic front view of an example of a bevel saw, according to the present disclosure, illustrating the first bevel angle.

FIG. 10 is a less schematic rear view of an example of a bevel saw according to the present disclosure.

FIG. 11 is a less schematic top view of an example of a bevel saw according to the present disclosure.

FIG. 12 is a less schematic bottom view of an example of a bevel saw according to the present disclosure.

FIG. 13 is a less schematic front view of an example of a bevel saw, according to the present disclosure, illustrating the second bevel angle.

FIG. 14 is an illustration of a guide plate and pins that may at least partially define a bevel guide, according to the present disclosure.

FIG. 15 is another illustration of the guide plate and pins of FIG. 14.

FIG. 16 illustrates an exploded view of a base plate and a bevel guide mount of bevel saws, according to the present disclosure.

FIG. 17 is a bottom view of the base plate of FIG. 16.

FIG. 18 is a cross-sectional view of the base plate of FIGS. 16-17 taken along line 18-18 of FIG. 17.

DETAILED DESCRIPTION AND BEST MODE OF THE DISCLOSURE

FIGS. 1-18 provide examples of bevel saws 10 and/or components thereof, according to the present disclosure. Elements that serve a similar, or at least substantially similar, purpose are labeled with like numbers in each of FIGS. 1-18, and these elements may not be discussed in detail herein with reference to each of FIGS. 1-18. Similarly, all elements may not be labeled in each of FIGS. 1-18, but reference numerals associated therewith may be utilized herein for consistency. Elements, components, and/or features that are discussed herein with reference to one or more of FIGS. 1-18 may be included in and/or utilized with any of FIGS. 1-18 without departing from the scope of the present disclosure.

In general, elements that are likely to be included in a particular embodiment are illustrated in solid lines, while elements that are optional are illustrated in dashed lines. However, elements that are shown in solid lines may not be essential to all embodiments and, in some embodiments, may be omitted without departing from the scope of the present disclosure.

FIG. 1 is a schematic front view illustrating examples of bevel saws 10, according to the present disclosure, and illustrating a first bevel angle 613, while FIG. 2 is another schematic front view of the bevel saw of FIG. 1 illustrating a second bevel angle 614. FIG. 3 is a schematic side view of the bevel saws of FIGS. 1-2, while FIGS. 4-13 are less schematic illustrations of an example of a bevel saw 10 according to the present disclosure. More specifically, FIG. 4 illustrates a top profile view of bevel saw 10, and FIG. 5 illustrates a right side view of bevel saw 10. FIG. 6 illustrates a left side view of bevel saw 10 illustrating the bevel saw in a plunged orientation 52, FIG. 7 illustrates the left side view of bevel saw 10 illustrating the bevel saw in a retracted orientation 54, and FIG. 8 illustrates the left side view of FIG. 7 with several covers removed. FIG. 9 is a front view of bevel saw 10 illustrating first bevel angle 613, FIG. 10 is a rear view of bevel saw 10, and FIG. 11 is a top view of bevel saw 10. FIG. 12 is a bottom view of bevel saw 10, and FIG. 13 is another front view of bevel saw 10 illustrating second bevel angle 614.

As illustrated collectively by FIGS. 1-13, bevel saws 10 include a motor 90 that includes a motor shaft 92 configured to rotate about a shaft rotational axis 94. Bevel saws 10 also include an arbor 100 configured to receive a torque from motor 90 when motor shaft 92 rotates about the shaft rotational axis. Receipt of the torque may cause arbor 100 to rotate about an arbor rotational axis 102. As illustrated in dashed lines in FIGS. 1-3 and in solid lines in FIGS. 5-10 and 12-13, bevel saws 10 also may include a circular saw blade 200. Circular saw blade 200, when present, may be operatively attached to the bevel saw via arbor 100 and/or may be configured for rotational movement with the arbor. Stated another way, rotation of arbor 100, such as about arbor rotational axis 102, may cause circular saw blade 200 to rotate, such as within a blade plane 202, as illustrated in FIGS. 1-3, 5-10, and 12-13. Rotation of circular saw blade 200 may facilitate cutting of a workpiece 98 with the circular saw blade, as schematically illustrated in FIGS. 1-3.

Bevel saws 10 also include a base plate 304, which defines an arbor-facing side 308 and an arbor-opposed side 312. Arbor 100 is operatively attached to arbor-facing side 308 such that the arbor-facing side of the base plate faces toward the arbor.

Bevel saws 10 also include a bevel guide 600, which may be configured to selectively vary a bevel angle 612 between blade plane 202 and arbor-opposed side 312 of base plate 304, such as to selectively vary an angle of a bevel cut 99 that the bevel saws are configured to make within workpiece 98, as illustrated in FIGS. 1-2. This may include selective variation within a bevel cut angular range-of-motion, such as may be defined between, for example, first bevel angle 613 of FIGS. 1 and 9, and second bevel angle 614 of FIGS. 2 and 13. Examples of the bevel cut angular range-of-motion include angle ranges of at least 25 degrees, at least 30 degrees, at least 35 degrees, at least 40 degrees, at least 45 degrees, at most 70 degrees, at most 65 degrees, at most 60 degrees, at most 55 degrees, at most 50 degrees, and/or at most 45 degrees. As discussed in more detail herein, bevel guide 600 may be operatively attached to base plate 304 with, via, and/or utilizing a bevel guide mount 700.

Bevel saws 10 may include any suitable type or style of bevel saw that is adapted, configured, designed, and/or constructed to utilize a circular saw blade 200 to cut the workpiece. Stated another way, bevel saws 10 may include additional features that may not be required of all bevel saws 10, according to the present disclosure. Examples of such bevel saws 10 with additional features include a handheld bevel saw 12, a plunge saw 30 and/or a track saw 40, as schematically illustrated in FIGS. 1-3. In some examples, bevel saws 10 may include structures and/or features from two or more of the above saws, and/or may incorporate functionality of two or more of the above saws. As an example, and as discussed in more detail herein, a given bevel saw 10 may be and/or may incorporate functionality of handheld bevel saw 12, plunge saw 30, and/or track saw 40. Bevel saws 10 according to the present disclosure thus may include one or more of the features disclosed herein, but bevel saws 10 are not required to include all of the features disclosed herein.

Motor 90 may include any suitable structure that may provide the motive force for rotation of motor shaft 92 and/or for actuation of circular saw blade 200. Examples of motor 90 include an electric motor, an AC electric motor, a DC electric motor, a brushless DC motor, a variable-speed motor, and/or a single-speed motor.

As illustrated in dashed lines in FIGS. 1-3 and in solid lines in FIGS. 4, 6-8, and 10-11, bevel saws 10 may include a gripping region 60 that is configured to be gripped and/or held by a user during operation of the bevel saw. Gripping region 60, when present, also may be referred to herein as and/or may be a handle, or hand grip.

As also illustrated in dashed lines in FIGS. 1-3 and in solid lines in FIGS. 4 and 6-8, bevel saws 10 may include at least one switch 65. Switch(es) 65, when present, may be configured to be selectively actuated by the user of the bevel saw, such as to enable and/or permit electric current to be provided to at least one other component of the bevel saw and/or to permit powered operation of the at least one other component of the bevel saw. As examples, selective actuation of switch(es) 65 may be utilized to enable operation of a motor controller of the bevel saw, to selectively apply an electric current to motor 90, to enable the motor controller to selectively apply the electric current to the motor, and/or to permit, or direct, the motor to provide the motive force for rotation of the motor shaft.

In some examples, the electric current may be utilized to power, or to directly power, at least one other component of the bevel saw, such as motor 90. In some such examples, the electric current also may be referred to herein as an electric power signal. In some examples, the electric current may be an electric data signal that is sent to at least one other component of the bevel saw, such as the motor controller of the bevel saw. In some such examples, the electric current also may be referred to herein as a data signal and/or as an electric data signal. Examples of switch 65 include an electrical switch, a normally open electrical switch, a momentary electrical switch, and/or a locking momentary electrical switch.

Bevel saws 10 may include any suitable power source, and corresponding power structures, for powering motor 90. Examples of the power structures include a power supply structure 70, such as a power cord 72 and/or a battery 74, as illustrated in FIGS. 1-3.

As also illustrated in dashed lines in FIGS. 1-3 and in solid lines in FIGS. 4-13, bevel saws 10 may include a blade guard 80. Blade guard 80, when present, may be configured to cover, to house, and/or to contain at least a region of circular saw blade 200, such as to prevent, or to decrease a potential for, contact between the user and the circular saw blade. In some examples of bevel saws 10, blade guard 80 may include a retractable region. The retractable region may be configured to fold, rotate, and/or otherwise retract when the bevel saw is utilized to cut the workpiece. The retractable region additionally or alternatively may be referred to as a retracting region and/or a collapsing region.

In some examples, and as discussed, bevel saws 10 may include and/or be plunge saw 30. In examples of bevel saws 10 that are or include a plunge saw 30, arbor 100 may be configured to move relative to base plate 304, such as to selectively vary a region 320 of circular saw blade 200 that projects from the base plate and/or to selectively vary a depth-of-cut of the bevel saw. Arbor 100 may be operatively attached to arbor-facing side 308 of base plate 304 with, via, and/or utilizing a base plate pivot 316, as illustrated in dashed lines in FIGS. 1-3 and in solid lines in FIGS. 6-8 and 11-12. In such examples, arbor 100 and base plate 304 may be configured to rotate, relative to one another, about base plate pivot 316, such as to selectively vary region 320 of circular saw blade 200 that extends on arbor-opposed side 312 of the base plate, as perhaps best illustrated by the transition from the configuration that is illustrated in FIGS. 1-3, 5-6, 9-10, and 13, which illustrate a plunged orientation 52, to the configuration that is illustrated in FIGS. 7-8, which illustrate a retracted orientation 54.

Stated another way, arbor 100 may be configured to pivot relative to base plate 304 throughout a range of relative orientations, or relative angles, that may be bounded by the plunged orientation and the retracted orientation. For each relative orientation in this range of relative orientations, circular saw blade 200 may extend on arbor-opposed side 312 by a corresponding amount, thereby providing a corresponding maximum depth-of-cut for the bevel saw.

In some examples, and as discussed, bevel saws 10 may include and/or be track saw 40. In examples of bevel saws 10 that are or include a track saw 40, base plate 304 may include a rib-receiving channel 324, which may be configured to receive a raised elongate rib 44 of a track 42, as perhaps best illustrated in FIGS. 1-2. Track 42 also may be referred to herein as an elongate track 42 and may be formed from one or more elongate track segments, or track sections, 46, which may be operatively attached to one another to define any suitable track length. During operation of track saws 40, track 42 may be operatively attached, or clamped, to workpiece 98 such that an edge of the track corresponds to a desired cut line for the track saw. Subsequently, the track saw may be positioned, relative to the track, such that raised elongate rib 44 is positioned within rib-receiving channel 324; and the track saw then may be translated along at least a fraction of the length of the elongate track, thereby producing a straight cut along the desired cut line.

FIGS. 1-3 schematically illustrate examples of bevel saws 10 that include bevel guides 600, according to the present disclosure, and FIGS. 13-15 are less schematic illustrations of examples of components of a bevel saw 10 that emphasize an example of bevel guide 600, according to the present disclosure. As illustrated schematically in FIGS. 1-3 and less schematically in FIGS. 14-15, bevel guides 600 may include a guide plate 622. Guide plate 622 may include a first circular arc-shaped slot 628 and a second circular arc-shaped slot 640. As illustrated in FIGS. 1-3 and 15, first circular arc-shaped slot 628 may have a first radius of curvature 632, which may extend from a first origin 636. Similarly, second circular arc-shaped slot 640 may have a second radius of curvature 644, which may extend from a second origin 648. Second origin 648 is spaced apart from first origin 636. As such, first circular arc-shaped slot 628 and second circular arc-shaped slot 640 may be referred to herein as and/or may be non-concentric circular arc-shaped slots.

The first radius of curvature and the second radius of curvature both may be greater than zero, or have a nonzero magnitude. In addition, first radius of curvature 632 may differ from second radius of curvature 644. As examples, a ratio of the first radius of curvature to the second radius of curvature may be at least 1.25, at least 1.5, at least 1.75, at least 2, at least 2.25, at least 2.5, at least 2.75, at least 3, at least 3.25, at least 3.5, at least 3.75, at least 4, at most 6, at most 5.5, at most 5, at most 4.5, at most 4, at most 3.5, and/or at most 3. The first radius of curvature and/or the second radius of curvature may have and/or define any suitable magnitude. Examples of a magnitude of the first radius of curvature include at least 25 mm, at least 30 mm, at least 35 mm, at least 40 mm, at least 45 mm, at least 50 mm, at least 55 mm, at least 60 mm, at least 65 mm, at least 70 mm, at least 75 mm, at least 80 mm, at least 85 mm, at least 90 mm, at least 95 mm, at least 100 mm, at most 200 mm, at most 175 mm, at most 150 mm, at most 125 mm, at most 100 mm, and/or at most 75 mm.

The second origin may be spaced apart from the first origin by any suitable amount. As an example, a distance between the first origin and the second origin may be at least a threshold fraction of the first radius of curvature. Examples of the threshold fraction of the first radius of curvature include at least 1%, at least 2.5%, at least 5%, at least 7.5%, at least 10%, at least 12.5%, at most 50%, at most 40%, at most 30%, at most 20%, at most 15%, and/or at most 10%.

In some examples, and with continued reference to FIGS. 1-3 and 14-15, bevel guide 600 may include a plurality of pins 652, including at least a first pin 656 and a second pin 660. First pin 656 may be configured to operatively translate along first circular arc-shaped slot 628 as bevel angle 612 is selectively varied throughout the bevel cut angular range-of-motion. Similarly, second pin 660 may be configured to operatively translate along second circular arc-shaped slot 640 as the bevel angle is selectively varied throughout the bevel cut angular range-of-motion.

The arbor of the bevel saw may be operatively attached to one of guide plate 622 and pins 652, and the base plate of the bevel saw may be operatively attached to the other of the guide plate and pins 652. In addition, the plurality of pins and the guide plate together attach the arbor to the base plate. With this in mind, guide plate 622 and pins 652 together may be utilized to locate, or to position, the base plate and the arbor, the motor, and/or the circular saw blade relative to one another during variation of bevel angle 612.

In some examples, and as illustrated in dashed lines in FIGS. 1-3 and 14-15, bevel guides 600 may include a plurality of bushings 670, such as a first bushing 672 and a second bushing 674. First bushing 672, when present, may extend around at least a region of first pin 656 that extends within first circular arc-shaped slot 628. In some examples, the first bushing may extend between and/or may be configured to separate, or to maintain a spaced-apart relationship between, the first pin and the first circular arc-shaped slot. In some examples, the first bushing may be configured to rotate around first pin 656 and/or within first circular arc-shaped slot 628. Similarly, second bushing 674, when present, may extend around at least a region of second pin 660 that extends within second circular arc-shaped slot 640. In some examples, the second bushing may extend between and/or may be configured to separate, or to maintain a spaced-apart relationship between, the second pin and the second circular arc-shaped slot. In some examples, the second bushing may be configured to rotate around second pin 660 and/or within second circular arc-shaped slot 640. Such a configuration may decrease frictional forces and/or wear within bevel guides 600 and/or may make it easier for the user to adjust the bevel saw throughout the bevel cut angular range-of-motion.

In some examples of bevel saws 10, and as illustrated in FIG. 3, the bevel saw may include a plurality of bevel guides 600, including at least a leading bevel guide 604 and a trailing bevel guide 608. Such a configuration may increase a rigidity and/or an accuracy of the bevel guides and/or may decrease a potential for unexpected variation in angle 612. In some such configurations, bevel saws 10 also may include a leading bevel guide mount 702, which may be configured to operatively attach leading bevel guide 604 to a leading region 305 of base plate 304, and a trailing bevel guide mount 704, which may be configured to operatively attach trailing bevel guide 608 to a trailing region 306 of the base plate.

Leading bevel guide 604 and trailing bevel guide 608 may include similar structures, such as those that are discussed herein with reference to bevel guides 600. As an example, leading bevel guide 604 may include a leading guide plate 623 that includes a first leading circular arc-shaped slot 629 and a second leading circular arc-shaped slot 641. First leading circular arc-shaped slot 629 may have a first leading radius of curvature 633 that may extend from a first leading origin 637. In addition, second leading circular arc-shaped slot 641 may have a second leading radius of curvature 645 that may extend from a second leading origin 649. Second leading origin 649 may be spaced-apart from first leading origin 637.

Similarly, trailing bevel guide 608 may include a trailing guide plate 625 that may include a first trailing circular arc-shaped slot 630 and a second trailing circular arc-shaped slot 642. First trailing circular arc-shaped slot 630 may have a first trailing radius of curvature 634 that may extend from a first trailing origin 638. In addition, second trailing circular arc-shaped slot 642 may have a second trailing radius of curvature 646 that may extend from a second trailing origin 650. Second trailing origin 650 may be spaced apart from first trailing origin 638.

Leading bevel guide 604 and trailing bevel guide 608 may have any suitable configuration and/or relative orientation. As an example, leading guide plate 623 may have and/or define a leading planar guide plate surface 624, and first leading circular arc-shaped slot 629 and/or second leading circular arc-shaped slot 641 may be defined therein. Similarly, trailing guide plate 625 may have and/or define a trailing planar guide plate surface 626, and first trailing circular arc-shaped slot 630 and/or second trailing circular arc-shaped slot 642 may be defined therein. In such a configuration, the trailing planar guide plate surface may face toward the leading planar guide plate surface.

As another example, leading guide plate 623 may extend parallel, or at least substantially parallel, to trailing guide plate 625. As yet another example, first leading radius of curvature 633 may be equal, or at least substantially equal, to first trailing radius of curvature 634. As another example, second leading radius of curvature 645 may be equal, or at least substantially equal, to second trailing radius of curvature 646. As yet another example, first leading origin 637 may be aligned with first trailing origin 638 along a first alignment axis 639. Additionally or alternatively, second leading origin 649 may be aligned with second trailing origin 650 along a second alignment axis 651. The second alignment axis may be parallel, or at least substantially parallel, to the first alignment axis.

As illustrated in dashed lines in FIGS. 1-3 and in solid lines in FIGS. 4-13, bevel guides 600 may include a bevel lock 680. Bevel lock 680, when present, may be configured to selectively retain bevel guide 600 at a selected bevel angle 612 within the bevel cut angular range-of-motion. Examples of bevel lock 680 include a cam, a cam lock, a set screw, a thumb screw, and/or a selectively actuated friction interface.

Bevel saws 10, including bevel guides 600, according to the present disclosure, may provide distinct benefits over conventional bevel saws that do not include bevel guides 600. As an example, bevel guides 600, including the configuration and/or relative orientation of first circular arc-shaped slot 628 and/or second circular arc-shaped slot 640 thereof, may maintain accurate, precise, and reproducible bevel angles 612 throughout the bevel cut angular range-of-motion, and/or with minimal hysteresis in the bevel angle. This may be in contrast to conventional bevel saws, where the structures utilized to vary the bevel angles may be inaccurate, imprecise, and/or may exhibit significant hysteresis.

As another example, bevel guides 600, including the configuration and/or relative orientation of first circular arc-shaped slot 628 and/or second circular arc-shaped slot 640 thereof, may permit bevel saws 10 to maintain constant, or at least substantially constant, a location, at which circular saw blade 200 intersects arbor-opposed side 312 of base plate 304. An example of such a location is illustrated in FIGS. 1-2 and 13 as location 620. This may include maintaining location 620 constant, or at least substantially constant, as angle 612 is varied throughout the bevel cut angular range-of-motion. Stated another way, bevel saws 10 may be configured to such that, as bevel angle 612 is varied throughout the bevel cut angular range-of-motion, a location of blade plane 202 within an arbor-opposed side plane that is defined by arbor-opposed side 312 of base plate 304 may vary by less than a threshold variation amount and/or distance. Examples of the threshold variation amount and/or distance include 0 millimeters (mm), at least 0.01 millimeters (mm), at least 0.05 mm, at least 0.1 mm, at least 0.15 mm, at least 0 2 mm, at most 5 mm, at most 4 mm, at most 3 mm, at most 2 mm, at most 1 mm, at most 0.5 mm, at most 0.25 mm, at most 0.1 mm, at most 0.05 mm, and/or at most 0.01 mm. This may be in contrast with conventional bevel saws, wherein the location of the blade plane may vary significantly with the bevel angle.

FIGS. 16-18 are less schematic illustrations of examples of components of a bevel saw 10 that emphasize an example of a bevel guide mount 700, according to the present disclosure. More specifically, FIG. 16 illustrates an exploded view of a base plate 304 and bevel guide mount 700 of bevel saws 10, and FIG. 17 is a bottom view of the base plate of FIG. 16. FIG. 18 is a cross-sectional view of the base plate of FIGS. 16-17 taken along line 18-18 of FIG. 17.

Bevel saws 10 of FIGS. 16-18 may include and/or be more detailed and/or different illustrations, views, and/or examples of bevel saws 10 of FIGS. 1-15. As such, any of the structures, functions, and/or features disclosed herein with reference to bevel saws 10 of FIGS. 16-18 may be (but are not required in all embodiments to be) included in and/or utilized with bevel saws 10 of FIGS. 1-15 without departing from the scope of the present disclosure. Similarly, any of the structures, functions, and/or features disclosed herein with reference to bevel saws 10 of FIGS. 1-15 may be (but are not required in all embodiments to be) included in and/or utilized with bevel saws 10 of FIGS. 16-18 without departing from the scope of the present disclosure.

Bevel guide mount 700 may include a bevel guide mount fastener 720, and in some examples may include only a single bevel guide mount fastener, that operatively attaches the bevel guide to the base plate. Bevel guide mount 700 also may include a reinforcing structure 732 that defines an opening 736. Bevel guide mount fastener 720 may extend through opening 736 when the bevel guide is operatively attached to the base plate via the bevel guide mount. In such a configuration, the bevel guide may be referred to as being compressed between the reinforcing structure and the base plate.

Bevel guide mount fastener 720 may include a bevel guide mount fastener head 724 that defines a fastener head transverse cross-sectional area. A contact area between reinforcing structure 732 and bevel guide 600 may be at least a threshold multiple of the fastener head transverse cross-sectional area. Such configuration may increase a compressive force that may be applied to bevel guide 600 by bevel guide mount fastener 720 without damage to the bevel guide. Additionally or alternatively, such a configuration may increase a holding force that bevel guide mount 700 applies to bevel guide 600 and/or may decrease a potential for loosening of the bevel guide mount fastener. Examples of the threshold multiple include threshold multiples of at least 4 times, at least 6 times, at least 8 times, at least 10 times, at least 15 times, at most 30 times, at most 20 times, at most 15 times, and/or at most 10 times the fastener head transverse cross-sectional area.

As perhaps best illustrated in FIG. 18, reinforcing structure 732 may extend on opposed sides of bevel guide mount fastener 720 such that the reinforcing structure defines at least two spaced-apart contact regions 738 with bevel guide 600. Opening 736 of reinforcing structure 732 may extend through a central region, or midpoint, of reinforcing structure 732, and contact regions 738 may extend equal, or at least substantially equal, distances away from opening 736 and/or away from bevel guide mount fastener 720. As also illustrated in FIG. 18, reinforcing structure 732 may not contact bevel guide 600 in a region 740 that is immediately below bevel guide mount fastener head 724. Such a configuration may cause bevel guide mount 700 to resist twisting and/or rotation between bevel guide 600 and base plate 304, such as about an elongate axis of the bevel guide mount fastener.

In some examples, base plate 304 and/or reinforcing structure 732 may have and/or define a high surface area region 744 that contacts the bevel guide. Presence of high surface area region 744 may decrease a potential for relative motion between bevel guide 600 and base plate 304 when bevel guide mount 700 operatively attaches the bevel guide to the base plate. Examples of high surface area region 744 include a ribbed region, a serrated region, a roughened region, and/or a plurality of projections.

As used herein, the term “and/or” placed between a first entity and a second entity means one of (1) the first entity, (2) the second entity, and (3) the first entity and the second entity. Multiple entities listed with “and/or” should be construed in the same manner, i.e., “one or more” of the entities so conjoined. Other entities may optionally be present other than the entities specifically identified by the “and/or” clause, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, a reference to “A and/or B,” when used in conjunction with open-ended language such as “comprising” may refer, in one embodiment, to A only (optionally including entities other than B); in another embodiment, to B only (optionally including entities other than A); in yet another embodiment, to both A and B (optionally including other entities). These entities may refer to elements, actions, structures, steps, operations, values, and the like.

As used herein, the phrase “at least one,” in reference to a list of one or more entities should be understood to mean at least one entity selected from any one or more of the entities in the list of entities, but not necessarily including at least one of each and every entity specifically listed within the list of entities and not excluding any combinations of entities in the list of entities. This definition also allows that entities may optionally be present other than the entities specifically identified within the list of entities to which the phrase “at least one” refers, whether related or unrelated to those entities specifically identified. Thus, as a non-limiting example, “at least one of A and B” (or, equivalently, “at least one of A or B,” or, equivalently “at least one of A and/or B”) may refer, in one embodiment, to at least one, optionally including more than one, A, with no B present (and optionally including entities other than B); in another embodiment, to at least one, optionally including more than one, B, with no A present (and optionally including entities other than A); in yet another embodiment, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other entities). In other words, the phrases “at least one,” “one or more,” and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B, and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and/or C” may mean A alone, B alone, C alone, A and B together, A and C together, B and C together, A, B, and C together, and optionally any of the above in combination with at least one other entity.

In the event that any patents, patent applications, or other references are incorporated by reference herein and (1) define a term in a manner that is inconsistent with and/or (2) are otherwise inconsistent with, either the non-incorporated portion of the present disclosure or any of the other incorporated references, the non-incorporated portion of the present disclosure shall control, and the term or incorporated disclosure therein shall only control with respect to the reference in which the term is defined and/or the incorporated disclosure was present originally.

As used herein the terms “adapted” and “configured” mean that the element, component, or other subject matter is designed and/or intended to perform a given function. Thus, the use of the terms “adapted” and “configured” should not be construed to mean that a given element, component, or other subject matter is simply “capable of” performing a given function but that the element, component, and/or other subject matter is specifically selected, created, implemented, utilized, programmed, and/or designed for the purpose of performing the function. It is also within the scope of the present disclosure that elements, components, and/or other recited subject matter that is recited as being adapted to perform a particular function may additionally or alternatively be described as being configured to perform that function, and vice versa.

As used herein, the phrase, “for example,” the phrase, “as an example,” and/or simply the term “example,” when used with reference to one or more components, features, details, structures, embodiments, and/or methods according to the present disclosure, are intended to convey that the described component, feature, detail, structure, embodiment, and/or method is an illustrative, non-exclusive example of components, features, details, structures, embodiments, and/or methods according to the present disclosure. Thus, the described component, feature, detail, structure, embodiment, and/or method is not intended to be limiting, required, or exclusive/exhaustive; and other components, features, details, structures, embodiments, and/or methods, including structurally and/or functionally similar and/or equivalent components, features, details, structures, embodiments, and/or methods, are also within the scope of the present disclosure.

As used herein, “at least substantially,” when modifying a degree or relationship, may include not only the recited “substantial” degree or relationship, but also the full extent of the recited degree or relationship. A substantial amount of a recited degree or relationship may include at least 75% of the recited degree or relationship. For example, an object that is at least substantially formed from a material includes objects for which at least 75% of the objects are formed from the material and also includes objects that are completely formed from the material. As another example, a first length that is at least substantially as long as a second length includes first lengths that are within 75% of the second length and also includes first lengths that are as long as the second length.

Illustrative, non-exclusive examples of bevel saws according to the present disclosure are presented in the following enumerated paragraphs.

A1. A bevel saw configured to make a bevel cut in a workpiece, the bevel saw comprising:

a motor including a motor shaft configured to rotate about a shaft rotational axis;

an arbor configured to operatively attach a circular saw blade to the bevel saw and rotate the circular saw blade within a blade plane and about an arbor rotational axis when the arbor receives a torque from the motor via rotation of the motor shaft about the shaft rotational axis;

a base plate that defines an arbor-facing side and an arbor-opposed side, wherein the arbor is operatively attached to the arbor-facing side of the base plate such that the arbor-facing side of the base plate faces toward the arbor; and

a bevel guide configured to selectively vary a bevel angle between the blade plane and the arbor-opposed side of the base plate within a bevel cut angular range-of-motion to selectively vary an angle of the bevel cut within the workpiece.

A2. The bevel saw of paragraph A1, wherein the bevel guide includes a guide plate that includes:

(i) a first circular arc-shaped slot that has a first radius of curvature that extends from a first origin; and

(ii) a second circular arc-shaped slot that has a second radius of curvature that extends from a second origin that is spaced apart from the first origin.

A3. The bevel saw of paragraph A2, wherein the first radius of curvature differs from the second radius of curvature.

A4. The bevel saw of any of paragraphs A2-A3, wherein a ratio of the first radius of curvature to the second radius of curvature is at least one of:

(i) at least 1.25, at least 1.5, at least 1.75, at least 2, at least 2.25, at least 2.5, at least 2.75, at least 3, at least 3.25, at least 3.5, at least 3.75, or at least 4; and

(ii) at most 6, at most 5.5, at most 5, at most 4.5, at most 4, at most 3.5, or at most 3.

A5. The bevel saw of any of paragraphs A2-A4, wherein the first radius of curvature is greater than zero, and further wherein the second radius of curvature is greater than zero.

A6. The bevel saw of any of paragraphs A2-A5, wherein a magnitude of the first radius of curvature is at least one of:

(i) at least 25 mm, at least 30 mm, at least 35 mm, at least 40 mm, at least 45 mm, at least 50 mm, at least 55 mm, at least 60 mm, at least 65 mm, at least 70 mm, at least 75 mm, at least 80 mm, at least 85 mm, at least 90 mm, at least 95 mm, or at least 100 mm; and

(ii) at most 200 mm, at most 175 mm, at most 150 mm, at most 125 mm, at most 100 mm, or at most 75 mm.

A7. The bevel saw of any of paragraphs A2-A6, wherein a distance between the first origin and the second origin is at least a threshold fraction of the first radius of curvature, optionally wherein the threshold fraction is at least one of:

(i) at least 1%, at least 2.5%, at least 5%, at least 7.5%, at least 10%, or at least 12.5%; and

(ii) at most 50%, at most 40%, at most 30%, at most 20%, at most 15%, or at most 10%.

A8. The bevel saw of any of paragraphs A2-A7, wherein the bevel guide further includes

a plurality of pins, and further wherein the plurality of pins includes:

(i) a first pin, which is configured to operatively translate along the first circular arc-shaped slot as the bevel angle is selectively varied throughout the bevel cut angular range-of-motion; and

(ii) a second pin, which is configured to operatively translate along the second circular arc-shaped slot as the bevel angle is selectively varied throughout the bevel cut angular range-of-motion.

A9. The bevel saw of paragraph A8, wherein the arbor is operatively attached to one of the guide plate and the plurality of pins, wherein the base plate is operatively attached to the other of the guide plate and the plurality of pins, and further wherein the guide plate and the plurality of pins together attach the arbor to the base plate.

A10. The bevel saw of any of paragraphs A8-A9, wherein the bevel guide further includes a plurality of bushings and further wherein the plurality of bushings includes:

(i) a first bushing that extends around at least a region of the first pin that extends within the first circular arc-shaped slot; and

(ii) a second bushing that extends around at least a region of the second pin that extends within the second circular arc-shaped slot.

A11. The bevel saw of any of paragraphs A1-A10, wherein the bevel guide is configured such that, as the bevel angle is selectively varied throughout the bevel cut angular range-of-motion, a location at which the blade plane intersects the arbor-opposed side of the base plate is constant, or at least substantially constant.

A12. The bevel saw of any of paragraphs A1-A11, wherein the bevel guide is configured such that, as the bevel angle is selectively varied throughout the bevel cut angular range-of-motion, a location of the blade plane within an arbor-opposed side plane, which is defined by the arbor-opposed side of the base plate, varies by less than a threshold variation amount, optionally wherein the threshold variation amount is at least one of:

(i) 0 millimeters (mm);

(ii) at least 0.01 mm, at least 0.05 mm, at least 0.1 mm, at least 0.15 mm, or at least 0.2 mm; and

(iii) at most 5 mm, at most 4 mm, at most 3 mm, at most 2 mm, at most 1 mm, at most 0.5 mm, at most 0.25 mm, at most 0.1 mm, at most 0.05 mm, or at most 0.01 mm.

A13. The bevel saw of any of paragraphs Al-Al2, wherein the bevel cut angular range-of motion is at least one of:

(i) at least 25 degrees, at least 30 degrees, at least 35 degrees, at least 40 degrees, or at least 45 degrees; and

(ii) at most 70 degrees, at most 65 degrees, at most 60 degrees, at most 55 degrees, at most 50 degrees, or at most 45 degrees.

A14. The bevel saw of any of paragraphs A1-A13, wherein the bevel guide is a leading bevel guide, and wherein the bevel saw further includes a trailing bevel guide.

A15. The bevel saw of paragraph A14, wherein the leading bevel guide includes a leading guide plate that includes a first leading circular arc-shaped slot, which has a first leading radius of curvature that extends from a first leading origin, and a second leading circular arc-shaped slot, which has a second leading radius of curvature that extends from a second leading origin that is spaced apart from the first leading origin.

A16. The bevel saw of paragraph A15, wherein the trailing bevel guide includes a trailing guide plate that includes a first trailing circular arc-shaped slot, which has a first trailing radius of curvature that extends from a first trailing origin, and a second trailing circular arc-shaped slot, which has a second trailing radius of curvature that extends from a second trailing origin that is spaced apart from the first trailing origin.

A17. The bevel saw of paragraph A16, wherein at least one of:

(i) the leading guide plate defines a leading planar guide plate surface, and the trailing guide plate defines a trailing planar guide plate surface that faces toward the leading planar guide plate surface;

(ii) the leading guide plate extends parallel, or at least substantially parallel, to the trailing guide plate;

(iii) the first leading radius of curvature is equal, or at least substantially equal, to the first trailing radius of curvature;

(iv) the second leading radius of curvature is equal, or at least substantially equal, to the second trailing radius of curvature;

(v) the first leading origin is aligned with the first trailing origin along a first alignment axis that extends parallel to the blade plane; and

(vi) the second leading origin is aligned with the second trailing origin along a second alignment axis that extends parallel to the blade plane and is parallel, or at least substantially parallel, to the first alignment axis.

A17.1 The bevel saw of any of paragraphs A1-A17, wherein the bevel guide further includes a bevel lock configured to selectively retain the bevel guide at a selected bevel angle.

A18. The bevel saw of any of paragraphs A1-A17.1, wherein the bevel guide operatively attaches the arbor to the base plate.

A19. The bevel saw of any of paragraphs A1-A18, wherein the bevel saw further includes a bevel guide mount configured to operatively attach the bevel guide to the base plate.

A20. The bevel saw of paragraph A19, wherein the bevel guide includes a/the leading bevel guide and a/the trailing bevel guide, and further wherein the bevel guide mount includes a leading bevel guide mount configured to operatively attach the leading bevel guide to a leading region of the base plate and a trailing bevel guide mount configured to operatively attach the trailing bevel guide to a trailing region of the base plate.

A21. The bevel saw of any of paragraphs A19-A20, wherein the bevel guide mount further includes a bevel guide mount fastener, and optionally only a single bevel guide mount fastener, that operatively attaches the bevel guide to the base plate.

A22. The bevel saw of paragraph A21, wherein the bevel guide mount further includes a reinforcing structure that defines an opening, wherein the bevel guide mount fastener extends through the opening such that the bevel guide is compressed between the reinforcing structure and the base plate.

A23. The bevel saw of paragraph A22, wherein the opening extends through a midpoint of the reinforcing structure, and further wherein the reinforcing structure includes contact regions that extend at least substantially equal, and optionally equal, distances away from the opening.

A24. The bevel saw of any of paragraphs A22-A23, wherein the bevel guide mount fastener includes a bevel guide mount fastener head that defines a fastener head transverse cross-sectional area, and further wherein a contact area between the reinforcing structure and the bevel guide is at least a threshold multiple of the fastener head transverse cross-sectional area.

A25. The bevel saw of paragraph A24, wherein the threshold multiple is at least 4 times, at least 6 times, at least 8 times, at least 10 times, at least 15 times, at most 30 times, at most 20 times, at most 15 times, or at most 10 times the fastener head transverse cross-sectional area.

A26. The bevel saw of any of paragraphs A1-A25, wherein the base plate further includes a high surface area region that contacts the bevel guide, optionally wherein the high surface area region includes at least one of:

(i) a ribbed region;

(ii) a serrated region;

(iii) a roughened region; and

(iv) a plurality of projections.

A27. The bevel saw of any of paragraphs A1-A26, wherein the motor includes an electric motor.

A28. The bevel saw of any of paragraphs A1-A27, wherein the bevel saw further includes a gripping region configured to be gripped by a user of the bevel saw during operation of the bevel saw to cut the workpiece.

A29. The bevel saw of any of paragraphs A1-A28, wherein the bevel saw further includes a switch configured to selectively apply an electric current to at least one other component of the bevel saw.

A30. The bevel saw of any of paragraphs A1-A29, wherein the bevel saw further includes a blade guard configured to prevent contact between a/the user and the saw blade.

A31. The bevel saw of paragraph A30, wherein the blade guard includes a retractable region configured to retract when the bevel saw is utilized to cut a/the workpiece.

A32. The bevel saw of any of paragraphs A1-A31, wherein the base plate is configured to position the workpiece and the bevel saw relative to one another when the workpiece is cut by the bevel saw.

A33. The bevel saw of any of paragraphs A1-A32, wherein the bevel saw further includes at least one of:

(i) a power cord configured to provide electric current to the bevel saw; and

(ii) a battery configured to provide electric current to the bevel saw.

A34. The bevel saw of any of paragraphs A1-A33, wherein the bevel saw is at least one of:

(i) a handheld bevel saw;

(ii) a plunge saw; and

(iii) a track saw.

A35. The bevel saw of any of paragraphs A1-A34, wherein the bevel saw is a/the plunge saw.

A36. The bevel saw of paragraph A35, wherein the arbor is operatively attached to the arbor-facing side of the base plate via a base plate pivot.

A37. The bevel saw of paragraph A36, wherein the arbor and the base plate are configured to operatively rotate, relative to one another, about the base plate pivot to selectively vary a region of the circular saw blade that extends on the arbor-opposed side of the base plate.

A38. The bevel saw of any of paragraphs A1-A37, wherein the bevel saw is a/the track saw.

A39. The bevel saw of paragraph A38, wherein the base plate further includes a rib-receiving channel configured to receive a raised elongate rib of a track.

A40. The bevel saw of paragraph A39, wherein the track saw further includes the track, and wherein the track includes the raised elongate rib.

A41. The bevel saw of any of paragraphs A1-A40, wherein the bevel saw includes the circular saw blade, optionally wherein the circular saw blade is operatively attached to the bevel saw via the arbor for rotational movement with the arbor about the arbor rotational axis.

INDUSTRIAL APPLICABILITY

The bevel saws disclosed herein are applicable to the power tool industry.

It is believed that the disclosure set forth above encompasses multiple distinct inventions with independent utility. While each of these inventions has been disclosed in its preferred form, the specific embodiments thereof as disclosed and illustrated herein are not to be considered in a limiting sense as numerous variations are possible. The subject matter of the inventions includes all novel and non-obvious combinations and subcombinations of the various elements, features, functions and/or properties disclosed herein. Similarly, where the claims recite “a” or “a first” element or the equivalent thereof, such claims should be understood to include incorporation of one or more such elements, neither requiring nor excluding two or more such elements.

It is believed that the following claims particularly point out certain combinations and subcombinations that are directed to one of the disclosed inventions and are novel and non-obvious. Inventions embodied in other combinations and subcombinations of features, functions, elements and/or properties may be claimed through amendment of the present claims or presentation of new claims in this or a related application. Such amended or new claims, whether they are directed to a different invention or directed to the same invention, whether different, broader, narrower, or equal in scope to the original claims, are also regarded as included within the subject matter of the inventions of the present disclosure.

BEVEL SAWS CONFIGURED TO MAKE A BEVEL CUT IN A WORKPIECE

Information

Publication Number

Date Filed

Date Published

Inventors

Original Assignees

CPC

International Classifications

Abstract

Description

Claims

RELATED APPLICATION

PCT Information

Provisional Applications (1)