Patent Application
20190118368
The present invention is related to easy to set up assembly of structures that can be used to be perform work on one or more workpiece or work item without causing damage to a base surface under the workpiece.
A challenge faced by woodworkers is the need to elevate their workpiece in order to ensure that there is clearance beneath it.
Historically, this type of problem has been solved using saw horses. The drawback of this solution is that saw horses can be relatively cumbersome and unstable in use and occupy a significant amount of space when being stored.
Alternate solutions in the form of standoff devices (e.g., bench cookies or painters pyramids) provide minimal support due to their small size. It is also awkward and relatively costly to use a sufficient number of such standoffs to support both a workpiece and any offcut.
One commonly used solution is to use a sheet of closed cell foam or plywood as a sacrificial member beneath the workpiece. Storage of closed cell foam as a sacrificial sheet is relatively expensive and makes it a relatively space-intensive solution.
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Throughout the course of discussion that follows, certain terms are used throughout such as “top”, “bottom”, “upper”, “lower”, “side”, “front”, “rear” and the like. These terms provide a suitable frame of reference with regard to the accompanying drawings, but are not intended to overly limit of the inventive concepts that are described herein, except where specifically and notably indicated.
The invention is inclusive of combinations of the embodiments or embodiments described herein. References to “a particular embodiment” or “embodiment” and the like refer to features that are present in at least one embodiment of the invention. Separate references to “an embodiment” or “particular embodiments” or “embodiments” or the like do not necessarily refer to the same embodiment or embodiments; however, such embodiments are not mutually exclusive, unless so indicated or as are readily apparent to one of skill in the art. The use of singular or plural in referring to “method” or “methods” and the like is not limiting.
As used herein, the term working surface is intended to refer to one or more surface over which and to the which a saddle of the present invention is to be used and coupled to, and the term workpiece is intended to refer to an item to be supported by the saddle over the working surface. The present invention is directed to inexpensive saddles that can be used to hold one or more work item or workpiece over a working surface. The saddle can be fastened to maintain its lateral position and orientation on the working surface. Pairs of saddles can be used to hold inexpensive and easily available lumber to create a support structure, upon which the work item can be placed horizontally. A lattice of the lumber can be used to ensure that the item and any offcuts are complete supported throughout working tool operation(s). The lumber used to create the support structure can be used in a sacrificial manner such that it can be cut when the item is being through-cut, and be replaced when needed.
The saddles can be fastened to maintain their position on the working surface via protruding fasteners. Versions of the fasteners can be screws or posts. When a post is used, the post can be configured to flexibly compress to fit snugly into and be retained in commonly dimensioned dog post holes, for example, ¾″ or 20 mm diameter dog post holes.
When the saddle is attached to an appropriately dimensioned post, it enables the saddles to be used with common woodworking fixtures which utilize dog holes (e.g., workbench, workmate), or other working surfaces.
A saddle, or saddle with a post provides a solution that allows the creation of a stable, elevated assembly to support work items in a wide variety of locations and environments. Its small size and rapid configuration enable the assembly to be easily stored, quickly set up when needed, and configuration of saddles changed easily as desired.
With the present invention, contact with a working surface by tools (circular saw, jigsaws, saws, routers, drills, cutters, etc.) used on an item supported over the working surface is minimized as is the opportunity to damage the tool. In addition, the present invention enables a space to be formed beneath the work item for accessory tools such as clamps to be used on the workpiece. The present invention also allows users to safely work with their tools, without having to worry about supporting workpieces with a free hand.
In one embodiment, the invention comprises: a method of supporting an item over one or more working surface, comprising the steps of: providing a first platform, the first platform comprising a top side, a bottom side, two opposite walls extending from the top side of the platform, and a first fastening structure extending from the bottom side, wherein the two opposite walls define a first channel and are disposed about a central first longitudinal axis; providing a second platform, the first platform comprising a top side, a bottom side, two opposite walls extending from the top side of the platform, and a second fastening structure extending from the bottom side, wherein the two opposite walls define a second channel and are disposed about a central second longitudinal axis; providing a third platform, the third platform comprising a top side, a bottom side, two opposite walls extending from the top side of the platform, and a third fastening structure extending from the bottom side, wherein the two opposite walls define a third channel and are disposed about a central third longitudinal axis; providing a fourth platform, the fourth platform comprising a top side, a bottom side, two opposite walls extending from the top side of the platform, and a fourth fastening structure extending from the bottom side, wherein the two opposite walls define a fourth channel and are disposed about a central second longitudinal axis; positioning the first platform over the one or more working surface; positioning the second platform over the one or more working surface; positioning the third platform over the one or more working surface; positioning the fourth platform over the one or more working surface; securing the first platform over the one or more working surface via the first fastening structure; securing the second platform over the one or more working surface via the second fastening structure; securing the third platform over the one or more working surface via the third fastening structure; securing the fourth platform over the one or more working surface via the fourth fastening structure; and positioning a first piece of lumber between the two opposite walls of the first platform and the two opposite walls of the second platform; and positioning a second piece of lumber between the two opposite walls of the third platform and the two opposite walls of the fourth platform. In one embodiment, the one or more working surface consists of a single surface. In one embodiment, the one or more working surface comprises at least two working surfaces. In one embodiment, the steps of positioning include aligning the longitudinal axis of the first platform and the longitudinal axis of the second platform to respective longitudinal axes defined by the ends of the first piece of sacrificial material (for example but not limited to lumber, foam sheets, foam pieces, cardboard tubes and other suitable materials), and aligning the longitudinal axis of the third platform and the longitudinal axis of the fourth platform to respective longitudinal axes defined by the ends of the second piece of sacrificial material (for example but not limited to lumber, foam sheets, foam pieces, cardboard tubes and other suitable materials). In one embodiment, the steps of aligning comprise rotating the first, second, third and fourth platforms about a longitudinal axis defined by their respective fastening structure. In one embodiment, the invention further comprises a step of placing the item on the first piece of lumber and the second piece of lumber. In one embodiment, the invention further comprises performing an operation on the item, the operation selected from the group comprising: cutting, sawing, drilling and routing. In one embodiment, the operation is performed without damaging the one or more working surface.
In one embodiment, the present invention comprises: an apparatus for supporting an item over a working surface, comprising: a first platform comprising a top side, a bottom side, two opposite walls extending from the top side of the platform, and a first fastener extending from the bottom side, wherein the first fastener comprises one or more curved outer surface, wherein the top side and two opposite walls define a first channel configured to receive the wood within the channel, wherein the apparatus is configured such that with the first fastener inserted into an opening in the working surface, lateral movement of the first platform relative to the working surface is limited. In one embodiment, the first fastener is selected from the group consisting of a screw, a nail, an expansion pin, a bolt, a rivet and a post comprised of one or more structure. In one embodiment, the first fastener comprises a top end and a bottom end, wherein the top end of the first fastener is coupled to the bottom side of the platform. In one embodiment, the first fastener comprises a top end and a bottom end, wherein the top end is coupled to the bottom side platform by a second fastener. In one embodiment, the second fastener is selected from the group consisting of: screw, a nail, an expansion pin and a bolt. In one embodiment, the first platform comprises at least one opening, and wherein the first platform is coupled to the first fastener via the at least one opening. In one embodiment, the two opposite walls of each channel are flexible.
In one embodiment, the present invention comprises: a system for supporting an item over a working surface, comprising: a first platform comprising a top side, a bottom side, two opposite walls extending from the top side of the platform, at least one opening, and a first fastener, wherein the top side and two walls define a first channel, wherein the first platform is configured such that with the first fastener inserted into the at least one opening of the first platform and an opening in a working surface the first platform is fixedly rotatable about a longitudinal axis of the first fastener; and a second platform comprising a top side, a bottom side, two opposite walls extending from the top side of the platform, at least one opening, and a second fastener, wherein the top side and two walls define a second channel, wherein the second platform is configured such that with the second fastener inserted into the at least one opening of the second platform and an opening in the working surface the second platform is fixedly rotatable about a longitudinal axis of the second fastener. In one embodiment, the first and second fastener each comprise at least one outer wall that is flexible. In one embodiment, the two opposite walls are flexible. In one embodiment, the two walls of the channel comprise surfaces that are not parallel. In one embodiment, the two walls comprise surfaces that define surfaces of ribs that provide support to the two opposite walls. In one embodiment, the first fastener and the second fastener each comprise a flexible post, where the post is flexible in its diameter and not in along its central axis. In one embodiment, the system further comprises a piece of 1-by or 2-by lumber, and wherein the first channel and the second channel are configured to receive and snugly retain the lumber.
In one embodiment, the present invention comprises: a system for supporting and item, comprising: a first platform comprising a top side, an opposite bottom side, and two opposite walls extending from the top side of the platform, wherein the top side and two opposite walls define a first channel configured to receive the wood within the recess; and a second platform comprising a top side, an opposite bottom side, and two opposite walls extending from the top side of the platform, wherein the top side and two opposite walls define a second channel configured to receive the wood within the recess, wherein the bottom side of the first and second platform is defined by a perimeter that has four sides with the same shape. In one embodiment, the bottom side of the first platform is joined to the bottom side of the second platform. In one embodiment the invention further comprises a fastener, wherein the first platform comprises a first opening and the second platform comprise a second opening, and wherein the bottom side of the first platform is joined to the bottom side of the second platform via insertion of a fastener in the first opening and the second opening.
In one embodiment, the present invention comprises: a kit for supporting an item over a working surface, comprising: a container for holding at least one piece of lumber; at least two platforms, each platform comprising a top side, a bottom side, two opposite walls extending from the top side of the platform, and an opening, wherein: the two opposite walls define a channel configured to receive and snugly retain the lumber; and at least 2 fasteners, each fastener configured to be coupled to a respective platform via the opening. In one embodiment, the invention further comprises least 2 posts, each configured to be coupled to the bottom side of a respective platform. In one embodiment, the at least one piece of lumber is selected from the group consisting of: 1-by and 2-by lumber. In one embodiment, the container comprises a soft bag configured to carry the lumber either entirely within the bag or partially within the bag.
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Saddle 100 further comprises two walls 102 on either side of channel 120, with each wall comprised of an inner surface 110 and an external surface 137 coupled to and extending from the platform 101 to the top end 114. In one embodiment, inner surface 110 is a planar surface that has a width that is longer in a horizontal longitudinal direction than its height in a vertical direction. In one embodiment, the two walls 102 are supported by a plurality of ribs 106. Ribs 106 comprise a horizontal thickness between the inner surface and the external surface that decreases in an upward direction from the platform such that the ribs 106 provide less lateral resistance to forces applied orthogonally to the walls 102 at their top end 114 than at their bottom end 115, which enable the walls to flex more at their top than at their bottom. In one embodiment, walls 102 are not parallel to each other. In one embodiment, each inner surface 110 is oriented at an angle that is slightly angled toward the center of the platform 101. In exemplary embodiments, a distance between the inner surfaces 110 is dimensioned to accommodate standardized 1-by or 2-by width lumber, for example, but not limited to, 1×2, 1×3, 1×4, 2×2, and 2×3 lumber. In one embodiment, each inner surface 110 has a bottom end 111 and a top end 112, where in an exemplary embodiment, a distance between the inner surfaces 110 at respective bottom ends 111 is 1.51 inches and a distance between inner surfaces 110 at respective top ends 112 is 1.45 inches, which dimensions those skilled in the art will identify as being approximately that of the nominal widths of 2×2, 2×3 and 2×4 lumber. In another exemplary embodiment, a distance between inner surfaces 110 at respective bottom ends 111 is 0.76 inches and a distance between inner surfaces at respective bottom ends 112 is 0.70 inches, which dimensions those skilled in the art will identify as being approximately that of the nominal widths of 1×2, 1×3 and 1×4 lumber. Although saddle 100 can be dimensioned to accept other sized lumber, the exemplary dimensions above have been identified as being preferred as they enable easily and commonly available on-site lumber to be found and used to quickly set up saddles as is described further below. In exemplary embodiments, the material comprises a hard plastic and/or polymer, for example, a polypropylene impact copolymer. In an embodiment of manufacture, saddle 100 is molded using techniques known to those skilled in the art.
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Further, although in one embodiment the inner surfaces of saddle 100 have been described to be non-parallel, it is contemplated in other embodiments that the two surfaces can be configured to be parallel.
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In an exemplary embodiment, where lumber 260a is a 1×3 piece of lumber (which is known to those skilled in the art to actually comprise a dimension 0.75×2.5 inches) and a distance between bottom ends of the inner surfaces of the channel of saddle 200a is 0.76 inches, and a distance between top ends of the inner surfaces of the channel of saddles 200a is 0.70 inches, lumber 260a is received between inner surfaces of channel 120 via an increase in the distance between the top end of the walls of the saddle that is enabled by flexing of the top of the walls of the saddle. In one embodiment of use, a distance between the walls 102 is increased via a slight back and forth rocking of lumber 260a along its longitudinal axis during downward movement of the lumber between the walls and toward the platform, where when the downward movement of the lumber is continued, the lumber 260a eventually rests and abuts the platform and is snugly retained by and between the walls of the saddle.
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In one embodiment of use, it is identified that lumber can be supported over a working surface with respective channels of at least two saddles oriented parallel with respect to each other. In another embodiment of use, it is identified that support over a working surface can be provided with respective channels of at least two saddles oriented co-linear with respect to each other. In another embodiment of use, it is identified that lumber used by the present invention does not necessarily need to be straight from end to end, as respective saddles used to receive ends of lumber can be easily oriented relative to one another to provide support to curved or slightly warped lumbers, albeit, with respective channels of the supports not being oriented co-linear with respect to each other.
In one embodiment, working surface 350 comprises a wood floor, for example, a wood floor of a structure or house under construction. In other embodiments, working surface 350 may comprise decking or a work bench.
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In one embodiment, saddle 400a is configured to resist lateral and tipping movements when placed onto a working surface 450 via use with a first fastener 490. In one embodiment, first fastener 490 comprises a screw. In other embodiments, fastener 490 comprises a nail, an expansion pin, a bolt, a rivet, or the like. In one embodiment, saddle 400a is configured to receive a bottom side and then a top side first fastener 490 through platform 401. In one embodiment, saddle 400a is configured to receive first fastener 490 through a preformed aperture in saddle 400a. In one embodiment of use, a saddle 400a is placed onto working surface 450 and a first fastener 490 is inserted through platform 401 until it extends below bottom end 415 of the saddle and into the working surface 450 at 451. Subsequently, as needed, saddle 400a can be rotated about first fastener 490 to a desired orientation relative to another saddle so as to enable ends of a piece of lumber to be inserted in both saddles without lateral movement and/or tipping of the lumber or the saddles.
In another embodiment, saddle 400b is configured to restrain lateral movement of the saddle when placed onto a working surface 450 via use with a second fastener 491. In one embodiment, saddle 400b is coupled to second fastener 491 via an aperture formed in the saddle. In one embodiment, the aperture in the saddle 400b is preformed in the platform of the saddle. In one embodiment, saddle 400b is coupled to second fastener 491 via insertion of a third fastener 492 through the platform of the saddle. In one embodiment of use, a coupled combination of saddle 400b and second fastener 491 is placed over a preformed opening 497 in a working surface 450, and the second fastener 491 is inserted into the preformed opening 497 until the bottom end of the saddle 400b rests against the working surface 450. Subsequently, as needed, saddle 400b can be rotated to a desired orientation so that its channel is aligned with a channel of another saddle to enable lumber to be inserted in both saddles without lateral movement and/or tipping as described above.
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In one embodiment, structures 619 comprise an inner wall 621 and an outer wall 622 disposed within a peripheral wall 605 of saddle 600. In one embodiment, structures 619 comprise one or more connecting portion 623, where inner wall 621 and outer wall 622 are joined by the one or more connecting portion. In one embodiment, inner wall 621 and outer wall 622 define a ring shape. In one embodiment, inner wall 621, outer wall 622, and one or more connecting portion 623 define one or more spaces or apertures 618 that have a shape that are configured to accommodate insertion of the top ends of the wings of second fastener 691. For example, in one embodiment, spaces 618 defined by the inner wall 621 and outer wall 622 are curved to accommodate curved outer 698 and inner 699 surfaces at the top ends of wings 693.
In one embodiment of use, top ends of wings 693 of a second fastener 691 are inserted into apertures 618 defined by the inner wall 621 and outer wall 622, and subsequently a first fastener (see first fastener 490 in
In another embodiment of use, a second fastener 691 having a 21 mm upper outer diameter above point 596 (see
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