The present device relates generally to flooring installation tools and more specifically to an improved toe-kick saw having enhanced safety features.
A toe-kick saw is a specialty circular saw used in residential floor remodeling. When a finished floor is to be replaced, this often means that the underlayment beneath the finished floor must also be replaced. The “finished floor” is the topmost, exposed layer of flooring selected for decor and utility in the room (typically vinyl, ceramic tile, carpet, hardwood or laminate plank). Beneath the finished floor is underlayment, which is an especially flat, finely finished material. The use of underlayment ensures the finished floor will be installed on a flat surface with no bumps which might poke through the finished floor or create irregularities. Beneath the underlayment is the rough subfloor (normally plywood) which is laid over the joists.
When a finished floor is to be replaced, it is often necessary to replace the underlayment as well. When new vinyl, ceramic tile, or hardwood floors are installed, adhesive is used to adhere the finished floor to the underlayment. In such cases, the finished floor cannot be removed from the underlayment without damaging it.
In many finished floor installations, especially in kitchens and bathrooms, cabinetry is encountered which may have toe-kicks. Toe-kicks are relieved areas at the bottom of the cabinet which allow a person to step closely to the cabinet without stubbing a toe. Often times the cabinetry is installed first before the finished floor is installed, and the cabinetry is installed on top of the underlayment. In the case of a hardwood finished floor, the cabinetry may even be installed on top of the finished floor as well.
Whenever cabinets with toe-kicks are installed on top of the underlayment or finished floor, removing only old underlayment and/or finished floor under the toe-kick can be very difficult. Using conventional hand tools, such as a hammer and chisel, the floor installer would have to chisel out the floor along the entire length of the toe-kick. This chiseling is difficult because the chisel can only be pointed into the corner at a 45 degree angle, not straight downward as required to effectively chisel the material. There is a clear danger of the hammer or chisel striking and damaging the cabinet face. Conventional power saws will not fit underneath the toe space. A specialized power saw is needed which can extend underneath and cut flush up against the inner wall of a toe space.
Toe-kick saws are available for this purpose. As shown in
The spindle extension assembly 150 of prior art toe-kick saw 100 includes spindle coupler 160, secondary spindle 200, and set screw 180 which connects spindle coupler 160 and secondary spindle 200. Other means to extend the spindle may be created by persons skilled in the art. For example, a spindle extension may be inserted into a hole in the spindle gear itself and keyed to a slot in the spindle gear. All such will be defined herein as a spindle extension assembly or spindle extension.
With reference to the prior art toe-kick saw 100 of
The prior art toe-kick saw 100 has a fixed guard 260 which is as small as possible in order to fit in as wide a range of toe-spaces as possible. A small blade guard 260, 280 also enables toe-kick saw 100 to come as close as possible to a wall surface of the room which may abut the toe-kick (such as, an inside corner area). However, users commonly misuse toe-kick saws. Despite instructions for proper usage and warnings to use the saw underneath toe-spaces only, and to cut forward and straight along the inner wall of the toe-space only, users misuse the tool by cutting outside the toe-space, by cutting sharp curves, or even by running the saw backwards by pulling it towards themselves. Such abuse may create the dangerous and well-known hazard common in the use of all circular saws called saw kickback. Saw kickback is caused when a saw blade may catch or become wedged on the edges of a saw kerf. The sudden stoppage of the blade may cause the saw to launch itself backward towards the user, creating a laceration hazard.
The fixed guard 260 does little to prevent saw misuse. While its small size is preferred, edges 360 are thin (0.160 inch or thinner) and do little to guide the saw straight forward or prevent it from being turned sharply. For this reason, fixed guard 260 will be defined herein as primarily a structure which “defines a blade housing.”
To prevent saw misuse, and provide additional safety in the case of saw misuse, features may be added to the fixed guard 260. Forward or rearward horizontal projections from the fixed guard 260 having wider flat surfaces could provide better guidance. Such wider flat surfaces might also prevent the saw from being turned sharply when they are flush against the inner wall of a toe-kick as prescribed for safe usage. Such wider flat surfaces may be designed so that they do not extend past the handles of the saw. Thus, they would not hinder the saw when it is started (or approaches) a wall abutting the toe-kick. Such a rearward or forward projection will be referred to herein as a rear toe-kick wall guide or a front toe-kick wall guide, respectively.
Other additional safety mechanisms may be mounted on a rear toe-kick wall guide or a front toe-kick wall guide, which were not possible before on prior art saws. Gripping devices may also be added to the movable guarding mechanisms to make it more difficult to pull the saw backwards towards the user.
It is an object of one or more embodiments to provide an improved blade guard for a toe-kick saw which provides improved guidance for the saw for straight cutting and prevents sharp turns when the saw is used as prescribed under a toe-kick.
It is an object of one or more embodiments to provide an improved blade guard for a toe-kick saw which may provide additional guarding in the event of saw kickback.
It is an object of one or more embodiments to provide an improved blade guard with a means of covering the circular saw blade, where said blade in previous saws was completely exposed.
It is an object of one or more embodiments to provide a means on the guarding mechanism to ensure that the saw is always pushed by a user in a direction which is forward or against the rotation of the circular saw blade.
It is an object of one or more embodiment to provide an improved blade guard for a toe-kick saw which allows the mounting of additional safety features, including an extended bumper surface, a secondary blade guard, and a dust control port.
The above objects have been achieved with an improved blade guard for a toe-kick saw having a fixed blade guard with either or both a rear toe-kick wall guide or a front toe-kick wall guide. Such a rear toe-kick wall guide or front toe-kick wall guide may also include an elongate flat surface which contacts flush against the inner wall of the toe space. Such a flat surface may assist in straight cutting and prevent the saw from making sharp turns. The rear toe-kick wall guide may also include a second surface which aids to deflect the saw away from a user in the event the saw kicks back and contacts the user, thus providing greater protection in the event of saw kickback.
On the fixed blade guard, a secondary retractable blade guard may be mounted. Such a secondary retractable blade guard may provide greater protection in the event of saw kickback by extending below the bottom edge of the fixed guard. Such a secondary retractable blade guard may also extend beyond the radius of the primary retractable blade guard to ensure that the primary retractable blade guard always has ample clearance to fully extend.
Onto either of the primary or secondary retractable blade guards, a gripping mechanism (e.g., such as rearward leaning spikes) may be mounted, which may prevent the saw from being moved backward (in a direction that is not against the rotation of the circular saw blade). Such spikes may dig into a floor surface to prevent the saw from being moved backward. The fixed blade guard may also include a dust port.
With reference to
As shown in
Next in the assembly is the mounting of spindle coupler 1180. Spindle coupler 1180 has a slot 1320 which accepts flats 1300 on secondary spindle 1240. As shown in
As shown in
Spindle extension assembly 1140 is housed within tube 1080. As previously explained, tube 1080 is inserted and fastened into opening 1060 of saw motor 1020. As shown in
Internal support for spindle extension assembly 1140 is provided within fixed guard 1400 by ball bearing 1220 and bushing 1460. Bushing 1460 is press fit into a reamed counterbored hole 1480. As shown in
When ball bearing 1220 is seated and fastened into counterbore 1490, the secondary spindle is prevented from sliding out by snap ring 1200. Spacer 1185 provides additional safety should snap ring 1200 fail. Spacer 1185 is larger in outside diameter than the center hole in ball bearing 1220, and thus also prevents spindle extension assembly 1140 from sliding out.
Practical problems of imprecise bearing alignment, runout, and motor vibration make manufacturing a circular saw with an extended spindle difficult. As shown in
As shown in
The distal end of secondary spindle 1240 projects a sufficient distance into blade housing 1500 to expose flats 1680. Flats 1680 engage blade driver 1700 which has a pair of cylindrical projections 1720. Cylindrical projections 1720 engage drive holes 1740 of small circular saw blade 1760. Small circular saw blade 1760 has an arbor hole 1780 which is precision countersunk on its outside surface to seat the pan-shaped head of blade screw 1800. Because blade screw 1800 is fully recessed into countersunk arbor 1780, the small circular saw blade 1760 has a flush face, and is able to cut as closely as possible to the inner wall of a toe-kick.
Fixed guard 1400 shows a new element, rear toe-kick wall guide 1820, which has an elongate flat area 1840. Elongate flat area 1840 serves as an improved guidance surface compared to edges 360 (
A “front/rear toe-kick wall guide” or “rear toe-kick wall guide” will be further defined as a portion of a fixed blade guard that is short enough to fit within a toe-kick and extends horizontally left or right more than ¼″ inch from either inside wall of the blade housing located within the fixed blade guard. Such a feature performs an additional function of providing guidance for the saw (i.e. it does not merely “define a blade housing” which is the primary function of the fixed guard). Such a front or rear toe-kick wall guide has an elongate wall engaging side face, allowing it to act as a guide against the inside wall of the toe-kick. It is preferred that said wall engaging side face be parallel with plane defined by the outer, vertical face of the circular saw blade. However, said wall engaging side face may also be at an angle in relation to the plane defined by the blade and be equally effective at preventing sharp turns, forming an extended bumper surface, or enabling the mounting of a secondary blade guard. The additional functions of the rear toe-kick wall guide will be more fully explained in the following.
Rear toe-kick wall guide 1820 also forms an extended bumper surface 1860 which is at a distance from blade housing 1500. As shown in
As shown in
Secondary movable guard 1980 has a bumper surface 2100 which is retracted into slot 2120 of rear toe-kick wall guide 1820 during a cutting operation. If toe-kick saw 1000 should kick back, secondary movable guard 1980 will extend automatically, and bumper surface 2100 will provide additional protection for the user. As shown in
An improved blade guard for a toe-kick saw having a front toe-kick wall guide or a rear toe-kick wall guide may have alternative embodiments. As previously explained, as shown in
In one alternative, as shown in
In another embodiment, the front toe-kick wall guide and rear toe-kick wall guide are shorter in their horizontal extension (as measured by their horizontal extension from the centerline of the spindle extension assembly) than the horizontal extension of the saw's handles. Such would be preferred so that the saw can cut as far as possible into a corner area where a wall may abut the toe-kick. Such a feature may be adapted to become a part of any of the embodiments.
In another embodiment, the secondary movable guard may have a longer radial extension than that of primary movable guard. This would ensure that whenever the secondary movable guard could extend into a fully extended guarding position, the primary movable guard would be unimpeded in its ability to extend. Making the secondary blade guard longer in radial extension would help ensure that the primary blade guard has adequate clearance to fully extend. Such is preferred and may become a part of any of the embodiments.
In
In
In
In
Putting the spike on a movable guard is preferred because it does not create a surface which is not flat on base 7060 of the fixed guard. If this base is not a flat surface, the blade is easily turned and wedged during use, promoting saw kickback. Furthermore, the saw would not cut to proper depth.
Such a spike or other frictional means to prevent the toe-kick saw from being moved backwards may be added to any of the embodiments herein to reduce the kickback hazard.
This application claims priority from U.S. provisional application No. 60/826,349, filed Sep. 20, 2006.
Number | Date | Country | |
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60826349 | Sep 2006 | US |