Patent Application
20200238561
The present invention relates generally to power tools, and more particularly to kerf forming apparatuses and methods. The apparatuses may be used as an accessory to a table saw to form a kerf in a workpiece, while the table saw simultaneously cuts the workpiece to length. Alternatively, the apparatuses may be used by themselves to from a kerf in a workpiece.
In light gauge steel stud wall construction, plywood backing spans between adjacent studs to provide support for heavy items (e.g., cabinets) that may be later attached to the wall. A typical steel stud has a C-shaped cross-section, with a short lip at the end of each of the flanges. A kerf—i.e., an elongate, linear groove or slot—is formed in the plywood backing to accept the lip. This helps to prevent the stud from twisting and bowing outwards when heavy items are attached to the wall. It also allows the plywood and face of stud to be flat. Without the kerf, the stud would deform when the screws are fastened through the stud to the backing.
Conventionally, the plywood backing is produced in a two-step process. First, a table saw is used to cut a plywood sheet to the length of the plywood backing between the studs. Second, a table saw, a portable circular saw, or a router, is subsequently used to form the kerf in the plywood backing. Even a wall of moderate size may require the production of hundreds of pieces of plywood backing. It would save time if the kerfs could be formed at the same time that the plywood sheets are cut to length.
In one aspect, the present invention comprises an apparatus for forming a kerf in a workpiece along a longitudinal direction, in use with a saw for simultaneously cutting the workpiece to length in a transverse direction perpendicular to the longitudinal direction. The saw may be a table saw which comprises a work surface for supporting the workpiece, a saw blade for cutting the workpiece in the longitudinal direction, and a fence having a selectively fixable position in the transverse direction relative to the saw blade.
In one embodiment, the apparatus comprises: (a) a fence-engaging member for engaging the fence to prevent movement of the apparatus in the transverse direction relative to the fence; (b) a rotary cutting tool for forming the kerf in the workpiece, the rotary cutting tool disposed above the work surface when the fence-engaging member engages the fence; and (c) a guide member for engaging the workpiece to prevent the workpiece from translating in the transverse direction on the work surface relative to the rotary cutting tool, while permitting the workpiece to translate in the longitudinal direction on the work surface relative to the rotary cutting tool, when the fence-engaging member engages the fence.
In one embodiment of the apparatus, the fence-engaging member defines an internal wall of a pocket that fits over and receives the fence.
In one embodiment of the apparatus, the fence-engaging member is detachable from the fence to permit the apparatus to be removed from the table saw.
In one embodiment of the apparatus, the apparatus further comprises at least one motor-actuated feed roller for engaging the workpiece while the roller rotates, to translate the workpiece in the longitudinal direction on the work surface relative to the rotary cutting tool.
In another aspect, the present invention comprises a method for simultaneously forming a kerf in a workpiece along a longitudinal direction and cutting the workpiece to length in a transverse direction perpendicular to the longitudinal direction. The method comprises the steps of: (a) providing a rotary cutting tool for forming the kerf in the workpiece, the rotary cutting tool disposed transversely apart from a saw blade for cutting the workpiece in the longitudinal direction; (b) simultaneously actuating the rotary cutting tool and the saw blade; and (c) moving the workpiece in the longitudinal direction to simultaneously engage the actuated rotary cutting tool and the actuated saw blade.
In one embodiment of the method, the saw blade is part of a table saw comprising a fence, and step (a) comprises attaching a part supporting the rotary cutting tool to the fence.
In one embodiment of the method, step (c) comprises using at least one motor-actuated feed roller for engaging the workpiece while the roller rotates, wherein friction between the roller and the workpiece causes movement of the workpiece.
In another aspect, the present invention comprises an apparatus for forming a kerf in a workpiece supported on a work surface. The apparatus comprises: (a) a rotary cutting tool for forming the kerf in the workpiece, the rotary cutting tool disposed above the work surface; (b) a guide member for engaging the workpiece to prevent the workpiece from translating in the transverse direction on the work surface relative to the rotary cutting tool, while permitting the workpiece to translate in the longitudinal direction on the work surface relative to the rotary cutting tool; and (c) at least one motor-actuated feed roller for engaging the workpiece while the roller rotates, to translate the workpiece in the longitudinal direction on the work surface relative to the rotary cutting tool.
In another aspect, the present invention comprises a method for forming a kerf in a workpiece. The method comprises the steps of: (a) actuating a rotary cutting tool for forming the kerf in the workpiece; and (b) using at least one motor-actuated feed roller for engaging the workpiece while the roller rotates, wherein friction between the roller and the workpiece causes the workpiece to move into engagement with the actuated rotary cutting tool.
In one embodiment of the method, the method further comprises providing a guide member that engages the workpiece to guide movement of the workpiece in a linear path when moved by the roller.
In embodiments of any of the apparatuses and any of the methods described above, the apparatuses and methods may further provide an enclosure that covers the rotary cutting tool to limit access to the rotary cutting tool when the fence-engaging member engages the fence. The enclosure may define a dust collection port through which dust generated by forming the kerf may be suctioned away from the rotary cutting tool.
In embodiments of any of the apparatuses and any of the methods described above, the rotary cutting tool may comprise an abrasive or toothed disc or blade rotatable about a transversely-extending axis, or a cutting bit rotatable about a vertical axis.
In the drawings shown in the specification, like elements may be assigned like reference numerals. The drawings are not necessarily to scale, with the emphasis instead placed upon the principles of the present invention. Additionally, each of the embodiments depicted are but one of a number of possible arrangements utilizing the fundamental concepts of the present invention.
The saw (10), by itself, may be a conventional table saw and does not form part of the present invention. The table saw (10) includes a work surface (12), a saw blade (14), and a fence (16). The saw blade (14) is for cutting the workpiece (20) in the longitudinal direction, and is actuated by an electric motor or other power source (not shown). In the embodiment shown in
The embodiment of the apparatus (100) shown in
The fence-engaging member (102) is used for engaging the fence (16) to prevent movement of the apparatus (100) relative to the fence (16) in the transverse direction. In the embodiment shown in
The rotary cutting tool (104) is used for forming the kerf (22) in the workpiece (20), and is actuated by an electric motor or other power source (not shown). “Rotary cutting tool”, as used herein, refers to any tool that, when rotated with sufficient torque relative to the workpiece, acts to remove material from the workpiece. Non-limiting examples of rotary cutting tools include an abrasive or toothed disc or blade that rotates about a transversely-extending axis, or a cutting bit that rotates about a vertical axis (such as a router bit). In the embodiment shown in
The guide member (106) is used for engaging the workpiece (20) to prevent the workpiece (20) from translating in the transverse direction on the work surface (12) relative to the rotary cutting tool (104), when the fence-engaging member (102) engages the fence (16). However, the guide member (106) permits the workpiece (20) to translate in the longitudinal direction on the work surface (12) relative to the rotary cutting tool (104), when the fence-engaging member (102) engages the fence (16). In the embodiment shown in
The optional feed rollers (108) actuated by the motor (110) are used to assist the user in advancing the workpiece (20) in the longitudinal direction along the work surface (12). As shown in
In the embodiment of
In use and operation of the embodiment of the apparatus (100) of
Alternatively, the embodiment of the apparatus (100) shown in
Interpretation.
Any term or expression not expressly defined herein shall have its commonly accepted definition understood by a person skilled in the art.
The corresponding structures, materials, acts, and equivalents of all means or steps plus function elements in the claims appended to this specification are intended to include any structure, material, or act for performing the function in combination with other claimed elements as specifically claimed.
References in the specification to “one embodiment”, “an embodiment”, etc., indicate that the embodiment described may include a particular aspect, feature, structure, or characteristic, but not every embodiment necessarily includes that aspect, feature, structure, or characteristic. Moreover, such phrases may, but do not necessarily, refer to the same embodiment referred to in other portions of the specification. Further, when a particular aspect, feature, structure, or characteristic is described in connection with an embodiment, it is within the knowledge of one skilled in the art to affect or connect such module, aspect, feature, structure, or characteristic with other embodiments, whether or not explicitly described. In other words, any module, element or feature may be combined with any other element or feature in different embodiments, unless there is an obvious or inherent incompatibility, or it is specifically excluded.
It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for the use of exclusive terminology, such as “solely,” “only,” and the like, in connection with the recitation of claim elements or use of a “negative” limitation. The terms “preferably,” “preferred,” “prefer,” “optionally,” “may,” and similar terms are used to indicate that an item, condition or step being referred to is an optional (not required) feature of the invention.
The singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. The term “and/or” means any one of the items, any combination of the items, or all of the items with which this term is associated. The phrase “one or more” is readily understood by one of skill in the art, particularly when read in context of its usage.
The term “about” can refer to a variation off 5%, ±10%, ±20%, or ±25% of the value specified. For example, “about 50” percent can in some embodiments carry a variation from 45 to 55 percent. For integer ranges, the term “about” can include one or two integers greater than and/or less than a recited integer at each end of the range. Unless indicated otherwise herein, the term “about” is intended to include values and ranges proximate to the recited range that are equivalent in terms of the functionality of the composition, or the embodiment.
As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges recited herein also encompass any and all possible sub-ranges and combinations of sub-ranges thereof, as well as the individual values making up the range, particularly integer values. A recited range includes each specific value, integer, decimal, or identity within the range. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, or tenths. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etc.
As will also be understood by one skilled in the art, all language such as “up to”, “at least”, “greater than”, “less than”, “more than”, “or more”, and the like, include the number recited and such terms refer to ranges that can be subsequently broken down into sub-ranges as discussed above. In the same manner, all ratios recited herein also include all sub-ratios falling within the broader ratio.
| Number | Date | Country | |
|---|---|---|---|
| 62798818 | Jan 2019 | US |
