This invention relates to saws, and more particularly, to a cutting guide for effecting a straight and accurate cut along a workpiece.
Power saws, such as circular saws, jig saws, miter saws and other saws are used extensively for cutting wood and other types of materials. When doing so, the cutting operation should be performed as accurately and safely as possible. In many instances, the cutting operation is to be performed along one or more straight line segments on a workpiece and therefore, performing straight cuts is essential to high quality carpentry and construction.
Guides that cooperate with the saw so as to execute a straight cut along a workpiece are generally well known. The guide helps to reduce the inaccuracies or errors that would otherwise result if the saw inadvertently moved or bumped during the cutting operation. Power saws generally include a housing in which an electrical motor is mounted and the motor in turn is operatively connected to an arbor on which the saw blade is mounted. For many types of saws, the saw further includes a saw plate or shoe that provides an opening through which the saw blade projects. The saw plate also supports the saw when positioned on a workpiece. A side edge of the saw plate is generally parallel to the saw blade and at a predetermined, fixed distance from the saw blade. The side edge of the saw plate is often used as a bearing surface against an edge of the saw guide during the cutting operation. The contact between the side edge of the saw plate and the edge of the saw guide keeps the blade of the saw along a straight path.
When a workpiece, such as a plank, a trim member or a 2×4, must be cut to a particular length, the length of the piece to be cut is measured, and then cut. When measuring a workpiece, the position of the cut line is identified and marked, such as, for example, by using a T-square and a pencil to trace the straight cut line, by laying down a chalk line to mark the cut line or by other means known in the art. The cut line, however, identifies the path of the saw blade, thus when using a guide, one must compensate for the position of the saw blade relative to the position of the bearing edge of the saw plate. In other words, one must measure from the cut line to account for the spacing between the side edge of the saw plate which abuts the saw guide and the position of the blade.
The distance between the saw blade and the side edge of the saw plate, hereafter referred to as the offset, is generally not a standard width and typically depends on not only the type of saw one is using for the cutting operation but also on the make and model of a particular type of saw. Thus the offset must be measured for the particular saw being used to make the desired cut. A second mark is then made on the workpiece at a distance from the desired cut line that corresponds to the offset for the saw being used to make the cut. In this way, when the saw is placed on the workpiece and the side edge of the saw plate positioned against an edge of the saw guide, the saw blade aligns with the desired cut line.
It is evident from the above description, however, that these calculations become quite tedious and prone to errors in the cutting process, especially when numerous workpieces having generally the same dimension must be cut. These drawbacks are exacerbated when a variety of different saws or models are used.
As such, a need exists for a cutting guide that reduces the potential for errors and inaccuracies when determining the position of the saw guide relative to the position of the desired cut line.
This invention provides a cutting guide that overcomes the above-mentioned and other problems by quickly and accurately locating the position of the saw guide relative to the cut line. The cutting guide includes a clamp, a saw guide pivotally coupled relative to the clamp and adapted to be juxtaposed to a surface of the workpiece, a guiding edge on the saw guide providing a bearing support to a portion of the saw so as to guide the saw during the cutting of the workpiece, and a cutting template coupled to the cutting guide and adapted to be juxtaposed to the surface of the workpiece. The cutting template is cuttable along a cut line so as to produce a template cutting edge. The template cutting edge identifies the position of the guiding edge of the saw guide relative to a cut line on the workpiece.
In one embodiment, the clamp includes a first clamping member fixedly secured to a lock bar extending from the first clamping member. A second clamping member is slidably coupled to the lock bar and is moveable so as to clamp varying sized workpieces therebetween. The second clamping member may be a quick release type with a handle having a first and second position. When the handle is in the first position the second clamping member is secured to the lock bar. When the handle is in the second position, the second clamping member is free to move along the lock bar. The cutting template may be fixedly secured to the clamp, such as with adhesives, or releasably secured thereto, such as by a tongue and groove connection between the first clamping member and the cutting template. In this way, a cutting template may be quickly and easily removed or inserted into the cutting guide. The saw guide may also be coupled to the clamp, such as at the first clamping member, and pivotally moveable between a plurality of positions. In one such position, the guiding edge of the saw guide is spaced from and generally parallel to the template cutting edge. To releasably secure the saw guide relative to the clamp, the saw guide includes a detent and the cutting template includes a plurality of recesses. The saw guide may be so secured when the detent engages one of the recesses.
In use, a user must first cut an uncut cutting template to form the template cutting edge and its associated first template portion that is saw and angle specific. To this end, the guiding edge of the saw guide is aligned relative to the cut line on the workpiece so as to account for the saw offset. If the cut line is angled, then the saw guide must be pivotally moved to correspond to the desired cut line angle. The cutting guide is then releasably clamped to the workpiece. A portion of the saw is then abutted against the guiding edge of the saw guide and moved along the guiding edge during the cutting operation. During the cutting operation, the saw cuts through both the workpiece and the cutting template and thereby forms the template cutting edge and its associated first template portion that is saw and angle specific. A second portion of the cutting template is simply discarded.
The as-formed cutting template may then be used to cut subsequent workpieces using the same saw and at the same angle without measuring or accounting for the saw offset. To this end, the cutting edge of the template is aligned with the desired cut line on the workpiece. The cutting guide is then releasably clamped to the workpiece. A portion of the saw is then abutted against the guiding edge of the saw guide and moved along the guiding edge during the cutting operation. During the cutting operation, the saw cuts through only the workpiece along the desired cut line. A user could have a plurality of cutting templates, each template having a different first portion configuration corresponding to different saws and different angled cuts.
In another embodiment of the invention, the cutting template may be coupled to the saw guide instead of the clamp. For example, the cutting template may be fixedly secured to the saw guide or releasably secured thereto, such as by a tongue and groove connection. In this way, a cutting template may be quickly and easily removed or inserted into the cutting guide. When the cutting template is coupled to the saw guide, the template cutting edge does not move relative to the saw guide as the saw guide is moved between the plurality of positions. This advantageously eliminates the need to have separate cutting templates corresponding to different angled cuts. In this case, it is contemplated that a user would have a plurality of cutting templates, each having a different first portion configuration corresponding only to different saws.
A clamp that may be used with the cutting guide includes a locking mechanism for securing the second clamping member to the lock bar at desired locations. To this end, the lock bar includes a plurality of teeth along an engaging edge of the lock bar. A hub adjacent the engaging edge is coupled to the second clamping member and is rotatable relative thereto. The hub includes a gear having a plurality of teeth along a tooth-engaging portion and no teeth along a blank portion. A handle is coupled to the hub to allow a user to conveniently rotate the hub and is moveable between a first and second position. In the first position, the teeth along the tooth-engaging portion engage and mesh with the teeth on the engaging edge of the lock bar. In the second position, the blank portion confronts the teeth of the lock bar. The locking mechanism further includes a locking switch coupled to the second clamping member and moveable between a locked and unlocked position. When in the locked position, the locking switch applies a frictional force to the hub that prevents relative movement between the hub and second clamping member. If the locking switch is locked when the respective teeth of the gear and lock bar are engaged, relative movement between the lock bar and second clamping member is prevented. When in the unlocked position, the hub may move relative to the second clamping member.
The features and objectives of this invention will become more readily apparent from the following Detailed Description taken in conjunction with the accompanying drawings.
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and, together with a general description of the invention given above, and the detailed description given below, serve to explain the invention.
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In general, however, a quick release mechanism 38 includes a handle 40 moveable between a first and second position. When handle 40 is in the first position, second clamping member 30 is secured to lock bar 36. When handle 40 is in the second position, second clamping member 30 is moveable along lock bar 36 and may be positioned adjacent workpiece 22 so as to secure workpiece 22 between first and second clamping members 24, 30 when handle 40 is moved back to the first position. In the trigger-type of locking mechanism 38 of
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So that the saw guide 14 does not move during a cutting operation, thereby affecting the accuracy of the cut, the position of the saw guide 14 relative to the cutting guide 10 is releasably fixed. As shown in
The cutting template 18 may be coupled to the cutting guide 10 in a number of ways known in the art. For instance, one way is to adhesively connect the cutting template 18 to first clamping member 24, as shown in
As shown in
The cutting template 18 may be integrally formed with saw guide 14 to form a unitary structure or assembly. For example, the saw guide 14 and cutting template 18 may be integrally molded from a suitable engineering plastic material. In this way, when a user changes saws, the integral saw guide 14 and cutting template 18 may be removed from cutting guide 10 and be replaced by a different saw guide 14 and cutting template 18 that corresponds to the saw that will subsequently be used. Alternately, the saw guide 14 and cutting template 18 may be provided as separate elements or components that are coupled through adhesion or through a frictional fit. For example, as shown in
Hub 106 includes a gear 111 having a plurality of teeth 112 along a tooth-engaging portion of the periphery of gear 111 and void of any teeth along a blank portion 113 of the periphery. The blank portion 113 may, for example, include a 90 degree segment of the gear 111. In one handle position, such as when the handle 110 is substantially parallel to the lock bar 36, the blank portion 113 of the gear faces the teeth 102 but does not contact teeth 102. When in such a position, the second clamping member 30 is free to move along lock bar 36. To lock the second clamping member 30 to the lock bar 36, the handle 110 is rotated in one direction, such as a counterclockwise direction. As the handle 110 is rotated, gear 111 is likewise rotated so that teeth 112 engage and mesh with teeth 102 on lock bar 36 to couple hub 106 to lock bar 36.
So as to selectively prevent the second clamping member 30 from moving relative to the first clamping member 24 during use of the cutting guide 10, locking mechanism 38 may further include a locking switch 114 coupled to second clamping member 30. To this end, hub 106 includes a top plate 116, wherein locking switch 114 is located along a periphery 118 of top plate 116. Second clamping member 30 includes a recess 120 into which a switch element 122 is inserted. Switch element 122 includes a cutout 124 into which a peripheral portion of top plate 116 is received so as to retain switch element 122 in recess 120. Switch element 122 is moveable, such as by a user, between a locked and unlocked position. In the unlocked position (
To this end, recess 120 includes a side wall 126 that is obliquely angled with respect to a base wall 128 of the recess 120. This configuration allows switch 122 to pivot about a bottom edge 130 within recess 120 between the locked and unlocked positions. To secure second clamping member 30 to lock bar 36, a user would turn the handle in a counterclockwise direction to engage teeth 102 with teeth 112. As the teeth are engaging each other, the user would then flip the switch element 122 in the clockwise direction to the locked position. When in the locked position, switch element 122 applies a frictional force tangential to top plate 116 so as to resist inadvertent rotation of handle 110 relative to second clamping member 30. Since teeth 102 and 112 are engaged undesirable movement of the second clamping member 30 relative to the first clamping member 24, which would loosen the clamp 12 from the workpiece 84, is prevented. To unlock the locking mechanism 38 and allow movement of second clamping member 30 along lock bar 36, a user would flip the switch element 122 in the counterclockwise direction and then turn the handle 110 in a clockwise direction. This removes the tangential frictional force so that hub 106 is can move relative to second clamping member 30 and allows the handle 110 to be moved so that blank portion 113 faces teeth 102 allowing second clamping member 30 to move relative to first clamping member 24 and along lock bar 36.
Another embodiment of a clamp similar that described above may be readily attained by substituting a hard rubber disk for gear 111 on hub 106. The hard rubber disc does not include any teeth along its periphery. Additionally, teeth 102 on the engaging edge 104 of lock bar 36 are replaced by a roughened surface. The engaging edge 104 may, for example, be roughened by knurls or other roughening patterns or elements. Second clamping member 30 may also include a support wall that engages and contacts an edge of lock bar 36 opposite to the engaging edge 104. In this way, the rubber disk is adapted to engage the lock bar 36, as will be explained below, and frictionally secure lock bar 36 between the rubber disc and the support wall. The frictional force then secures second clamping member 30 to lock bar 36.
It is desirable that when locking mechanism 38 is in an unlocked position, such that second clamping member 30 is free to move along lock bar 36, the rubber disk and roughened engaging edge 104 do not engage one another. To this end, pin 108 is not located at the geometric center of hub 106, but instead is positioned slightly off center and toward locking bar 36. This eccentric configuration advantageously allows the rubber disc on hub 106 to engage roughened engaging edge 104 on lock bar 36 when the handle 110 is moved in one direction, such as the counterclockwise direction. This eccentric configuration further advantageously allows the rubber disc on hub 106 to disengage roughened engaging edge 104 on lock bar 36 when the handle 110 is moved in the opposite direction, such as the clockwise direction, so as to permit movement of second clamping member 30 along lock bar 36. This alternate embodiment of the clamp may or may not include the locking switch 114, as previously described. It is contemplated that the friction created between the rubber disc and lock bar 36 and the support wall and lock bar 36 is sufficient to lock the second clamping member 30 to lock bar 36. However, locking switch 114 may be included to further secure second clamping member 30 to lock bar 36.
The invention as described herein has a number of advantages. The primary advantage is that, after the cutting template 18 is cut to produce the template cutting edge 66 on first template portion 62, a user no longer has to know or mark the position of the guiding edge 16 of the saw guide 14, but must only know the position of the cut line 86, which is the normal course of cutting operations. Removing this step greatly reduces the errors and mistakes made when compensating for the offset in the saw being used to make the cut. This also reduces the time to make the cuts on a workpiece, especially when there are numerous workpieces having the same type of cut configuration. Another advantage of the present invention is that because the cutting guide 10 is clamped onto the workpiece, the user may use two hands when operating the saw 19. This then allows a user to make a safer cut without sacrificing cutting accuracy. The safety of cutting operations is also improved by providing a rigid platform from which to start the cutting operation. In many instances, carpenters and other users do not have a platform or starting surface for which to operate the saw, such as a circular saw, before engaging the workpiece. In this invention, the cutting template 18 is sized to provide a platform for operating the saw prior to engaging the workpiece. This makes the entry into the workpiece cleaner and reduces the likelihood of the workpiece “kicking” or presenting other safety hazards.
The cutting guide 10 may also include other features frequently used in woodworking and construction applications. For instance, the saw guide may include a level indicator for gaging the orientation of the saw guide. Moreover, the saw guide and first clamping member may be configured to be in perpendicular relation to each other. When so configured, the cutting guide may also be used as a T-square. The saw guide and/or first clamping member may then include ruler markings or indicia of length typically found on a carpenter's square.
While this invention has been illustrated by the description of the various embodiments thereof, and while the embodiments have been described in considerable detail, it is not intended to restrict or in any way limit the scope of the appended claims to such detail. For instance, it should be understood that while the illustrated embodiments show a cutting guide directed towards cutting operations from left to right when the saw guide is angled, the cutting guide may also be configured to make cuts from right to left when the saw guide is angled.
Additional advantages and modifications will readily appear to those skilled in the art. The invention in its broader aspects is therefore not limited to the specific details, representative apparatus and methods and illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the scope or spirit of the general inventive concept.
This application is a continuation-in-part of U.S. application Ser. No. 10/801,278, filed on Mar. 16, 2004 and hereby incorporated by reference entirely.
Number | Date | Country | |
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Parent | 10801278 | Mar 2004 | US |
Child | 11061428 | Feb 2005 | US |