Extension Table Apparatus for Power Saw

This invention is directed to an extension table apparatus particularly useful in association with a miter saw. The apparatus includes a base which has its own retractable wheels and has removable legs so that the saw may be readily transported to and from the job. The left and right extension tables detachably attach to the miter saw table and each carries a fence for the positioning of a strip to be cut and adjustable stop to establish the correct cut length.

Miter saws are extensively used in finish carpentry. When finish coping, baseboard and other trim strips are applied, they must be accurately cut to length and accurately cut to the proper angle for joining the adjacent trim. The miter saw has been especially developed for this use. A miter saw has a table which carries a fence thereon. A rotary saw blade is pivoted about a swing axis and the blade can be swung down at least partially into a slot in the table. In addition, the saw is mounted to rotate about an upright axis so that the angle of the blade with respect to the fence can be adjusted. In this way, bevels or miter cuts are made.

For cost control and size convenience, the table length of such a miter saw is very limited. However, such saws are often used for cutting fairly long trim strips. As a result, there is much overhang and this overhang makes it difficult to make careful finish cuts. In addition, since the strips to be cut are generally longer than the table of the miter saw, there is no opportunity to clamp a stop on the table or fence. As a consequence each cut must be individually measured, which is both time-consuming and less accurate than the use of a proper stop.

While an extension table may simply be created for a miter saw, it must also be noted that such miter saws are usually taken to the job site so that large size or great weight seriously decreases the usefulness of an ordinary extension table into which a miter saw may be placed. For convenience, the extension table apparatus must be detachable and storable in a protected area. Furthermore, the apparatus must be useful in various locations so that it may be used supported on a work bench or on a floor and the table must be able to be properly aligned even when its support is uneven. Accordingly, there is need for a proper extension table apparatus for a miter saw.

In order to aid in the understanding of this invention, it can be stated in essentially summary form that it is directed to an extension table apparatus for a miter saw wherein left and right extension tables respectively carry left and right fences and are respectively detachably attached on the left and right ends of the table of a miter saw and are pivoted with respect thereto so that they may be aligned with the table of the miter saw. The extension tables each have adjustable supports to permit this alignment.

It is, thus, a purpose and advantage of this invention to provide an extension table apparatus for a miter saw wherein left and right extension tables are detachably attached to the miter saw table and are pivoted with respect thereto. Each of the extension tables has adjustable supports so that alignment can be achieved.

It is a further purpose and advantage of this invention to provide an extension table apparatus wherein the extension table carries thereon a fence and the fence carries a gauge thereon to indicate distance from the miter saw blade and the fence also carries an adjustable stop movable along the fence so as to define a predetermined distance from the miter saw blade.

It is another purpose and advantage of this invention to provide a base for a miter saw which is useable in conjunction with extension tables and a miter saw, with the base having removable legs thereon and having retractable wheels thereon so that the miter saw can be detached from the extension tables and can be moved to a new location.

It is another purpose and advantage of this invention to provide storage and protection for the extension tables when they are demounted from the miter saw with which they are associated.

The features of the present invention which are believed to be novel are set forth with particularity in the appended claims. The present invention, both as to its organization and manner of operation, together with further objects and advantages thereof, may be best understood by reference to the following description, taken in conjunction with the accompanying drawings.

FIG. 1 is an isometric view of the preferred embodiment of the extension table apparatus of this invention in association with a miter saw.

FIG. 2 is an enlarged section taken generally along line 2--2 of FIG. 1, with parts broken away.

FIG. 3 is an exploded isometric view of larger scale than FIG. 1, showing the connection between one extension table and the miter saw table, with parts broken away.

FIG. 4 is an enlarged view, as seen along the line 4--4 of FIG. 3, showing an extension table in association with the end of the miter saw table, with parts broken away.

FIG. 5 is a side-elevational view of the structure of FIG. 3, with parts broken away and parts taken in section, showing the extension table being moved towards the miter table for attachment thereto.

FIG. 6 is similar to FIG. 5, showing the connection completed.

FIG. 7 is a section taken generally along the line 7--7 of FIG. 6, with parts broken away.

FIG. 8 is an isometric view of the case and its cover, with parts broken away, for storage and transport of the extension tables.

FIG. 9 is an enlarged section taken generally along line 9--9 of FIG. 8, showing in dashed lines the extension tables stored therein.

FIG. 10 is an isometric view of the base for mounting of the miter saw thereon, for support and transport of the miter saw, and showing the support legs in place.

FIG. 11 is a view similar to FIG. 10 showing the legs of the base removed and showing the wheels lowered for transport of the saw.

FIG. 12 is a side-elevational view of the base showing the detachable mounting of the legs of the base and showing the deployable mounting of the wheels of the base.

FIG. 13 is an isometric view of the fences with index scale holders.

A typical example of a miter saw with which the extension table apparatus of this invention is associated is generally indicated at 10 in FIG. 1. The saw 10 has a table 12 on which are carried legs for the support of the saw. Front legs 14 and 16 are shown in FIG. 1, and there are corresponding rear legs under the table. The table has a top surface 18 on which sticks of wood to be cut are placed. Left and right saw table fences 20 and 22 are portions of a single fence member which is secured to the table, with the front surfaces thereof in alignment with each other. Swivel platform 24 forms part of the table and has a top surface in alignment with the surface 18. Swivel platform 24 rotates about a vertical axis so that its angular alignment with the fence can be adjusted. The swivel platform carries swing bearing 26 thereon in a position above and behind the fences. Swing arm 30 is pivoted on bearing 26 and rotatably carries saw blade 28 on its outer end on an axis parallel to the axis of swing bearing 26. The arm carries a motor for driving the saw blade and a guard for protecting the operator. When the saw blade is used to cut square ends on wood strips, the axes of the saw blade and swing bearing are parallel to the front faces of fences 20 and 22. When a bevel cut is desired, swivel platform 24 is rotated so that the plane in which the saw blade rotates is at an angle to the fences. Swivel platform 24 has a slot 32 therein which receives the blade as it is swung down. Such saws are used in finish carpentry and thus must be taken to the job site.

In order to aid in the transport of the miter saw, base 34 is provided therefor. Base 34 is in the form of a shallow box having closed top and sides. Top 36 has threaded holes therein, such as holes 38 and 40, by which the miter saw 10 is secured onto the base, such as bolts through the saw legs into the threaded holes.

The base 34 may be placed on a work bench or tailgate of a truck. In order to produce stability in that position, a rubber foot pad is positioned under each corner of the base.

Foot pads 42, 44 and 46 are seen in FIGS. 9 and 10. A similar pad is under the far corner. A solid panel is provided under each end of the base, upon which these foot pads are located. The solid panels are indicated at 48 and 50 in FIG. 12. In order to support the base upon the floor, in the absence of a work bench, leg openings are provided in these panels, together with socketsin the space above-the panels to receive removable legs. Legs 52, 54 and 56 are indicated in FIG. 10 and there is a fourth leg under the far corner. Legs 52 and 54 are shown in phantom lines in FIG. 12, illustrating the angle of the legs in the sockets from the front of the base. These legs are telescoping so that the base may be level on an uneven floor and the table raised to the desired height. They may be slipped out of their sockets and stored when not in use. Storage space is provided through the base, with four leg holes 58 indicated at the right end of the base in FIGS. 9 and 10. When removed from their sockets, the legs can be inserted through these leg holes for storage as illustrated.

Panels 60 and 62 respectively lie adjacent panels 48 and 50 and are respectively hinged thereto by hinges 64 and 66. The panels can be swung from the closed position illustrated in FIG. 12 to an open position where they extend almost to the pads 42 and 44 respectively. Mounted on the bottom of each of the panels 60 and 62 when they are in the open position is a pair of wheels. One of the left pair is indicated at 68, and one of the right pair is indicated at 70 in FIGS. 9 and 12. When the wheels are swung down to the position in FIG. 9, then the base and miter saw carried thereon may be easily rolled to and from the job site. When at the job site, either on a work bench, tailgate of a truck or on its own legs, the wheels are stored within the base in the dotted line position shown in FIG. 12. Accordingly, the miter saw and its base can be conveniently handled.

As described above, it is desirable to detachably attach an extension table to each end of table 12 in order to permit the convenient cutting of longer wood. In addition, it is desirable to employ a stop in association with each extension table so that repetitive cutting can be conveniently achieved. Left extension table 72 and right extension table 74 are shown in FIG. 1. These tables are preferably mirror-image identical, and the right extension table 74 is shown in more detail. Therefore, a description of its structure follows.

Table 74 is in the form of an inverted U-shaped channel having a top surface 76 on the top of its web and down-turned flanges 78 and 80. The web of the table is substantially the same width as the table 12 of the miter saw. Fence 82, described in more detail below, is secured to the top surface of the table and positioned so that it can be placed in alignment with fence 22. Securement of the left and right extension tables to the saw table is accomplished by a detachable connection. The detachable connection is illustrated in detail in FIGS. 3, 4, 5, 6 and 7. As seen in FIGS. 3, 4, 5 and 6, angle 84 is secured to the end of table 12. The outwardly extending flange 86 of the angle has mounted thereunder latch plate 88. As seen in FIG. 4, the latch plate is mounted on a pivot pin 90 and is held in place by fasteners 92 and 94 which extend through clearance holes to permit latch plate 88 to swing on the axis of pivot pin 90. The outer edge of latch plate 88 is rolled to form cylindrical bolt opening 96 in which latch bolts 98 and 100 are located. The bolts have handles 102 and 104, respectively, which extend out through L-shaped openings 106 and 108, respectively. Compression springs 110 and 112 respectively urge the bolts outward. In their retracted position, they are within the lateral confines of the latch plate 88, and in their extended position, they extend outward beyond the latch plate, as indicated in dashed lines in FIG. 4.

Latch receiver 114 is U-shaped and is positioned between the flanges 78 and 80. It is seen in exploded position in FIG. 3. Latch receiver 114 has its arms 116 and 118 sufficiently separated to embrace around latch plate 88, as seen in FIG. 4. The arms have latch openings 120 and 122 therein, and the latch openings are positioned so that they are aligned with the latch bolts when the extension table is in proper position. It should be noted that the view of FIG. 4 is in the upward direction so that the bolt handles 102 and 104 are directed downwardly when they are in the foot of the L-shaped openings to hold the bolts in the retracted position. This downward orientation is shown in FIG. 5. Latch operator 124, as seen in FIGS. 5, 6 and 7, is positioned between the arms of latch receiver 114. It is positioned so that as the extension table is brought into position, the latch operator engages bolt handles 102 and 104 to move them off the foot of the L-shaped opening into the length of it so that the springs 110 and 112 push the latch bolts outwardly. As they move outwardly, they engage in the latch openings 120 and 122 and the corresponding openings in the flanges 78 and 80.

There is no attempt by that connection to support the outer end of the extension table. The top surface 76 of the extension table should lie in the same plane as the top surface 18 of the saw table. Similarly, the front face 126 of fence 82 should lie in the same plane as the front face of fence 22. When the base 34 is resting on a work bench 128, as shown in dashed lines in FIG. 1, hinged support panels, such as panel 130, are swung down from a detented position within the confines of the channel of extension table 74 to a lowered position shown in solid fold lines in FIG. 1 where the support panel is swung down onto the top of the work bench to provide the desired physical support. If desired, adjustable screw legs can be provided under the support panel to provide adjustment for surface irregularity. A similar support panel 132 is provided under left extension table 72. At the outer end of the extension tables 74, legs are provided which can be employed to support the extension table when the base 34 is not on a work bench but supported on the floor by means of its own legs. As is seen in FIG. 1, legs 134 and 136 are mounted on bar 138 which is hinged to the under side of extension table 74. Bar 138 and legs 134 and 136 mounted thereon are sized to lie within the confines of the U-shaped recess in the bottom of the extension table when they are in the folded position. As is seen in FIG. 2, spring clip 140 is positioned to receive the leg 136 when it is in its folded-in position. A similar spring clip is provided for the leg 134. Each of the legs 134 and 136 is telescoping so that the outer end of the extension table can be positioned in proper alignment with saw table 12. If desired, a similar set of hinged legs is provided under the outer end of extension table 72. By means of these supports for the extension tables, the extension tables can be aligned with the table surface and fence of the miter saw.

In order to permit quick and accurate positioning of sticks of wood to be cut so that the resultant cuts provide an accurate cut length, an index scale is provided. As is seen in FIG. 2, fence 82 has a longitudinal groove therein. When the table 74 is aligned, the groove 142 aligns with a similar groove in fence 22. Scale holder 144 is positioned therein. When only long lengths of wood are to be cut, the scale holder 144 need not extend onto fence 22 but may terminate at the left end of fence 82. However, to maximize utility, the long scale holder 144 is shown. Scale holder 144 carries scale 146 on an upper angular face where it is clearly visible to the operator. When zero on the scale is set to the side of the saw blade, it can be used to directly position wood to be cut. However, quite often it is desirable to make repetitive cuts. In that circumstance, a stop is used.

Stop 148 is configured to fit adjacent the front of fence 82 on the front and top of index scale holder 144. In addition, index scale holder 144 has a Tee-slot 150. Nut 152 is sized to slide within Tee-slot 150 and is engaged by clamp bolt 154. When the clamp bolt is tightened, the stop is clamped to the face of index scale holder 144, and thus is secured with respect to the table 74 and fence 82. Stop 148 has a rectangular channel 155, open at both ends, which accepts interchangeable stop members. Stop member 156, for example, is in the active position and has a stop face directed towards the saw at a 45.degree. angle. Various stop members are interchangeable, so that they may be replaced on account of wear and on account of providing different angular stop faces, depending on the angle of the wood which rests against the stop face. Each of the stop faces is organized so that the position at which it stops the wood against the angular or square stop face is correct with respect to the reading on index scale 146. A spring-loaded pin 157 enters a corresponding hole in the stop member 156 to assure accurate alignment of the face. The stop 148 is provided with a window 158 which has a witness line therein so that accurate setting of the stop can be achieved.

In FIG. 1, the index scale holder 160 on fence 162 stops at the right end of fence 162. This structure permits use of the index scale on the left index scale holder and permits the use of the stop 148 on that scale holder, should the stop be desired on the left end. Since the index scale holder 160 stops at the right end of fence 162, the apparatus is easier to set up because the index scale holder 160 does not need to go into fence 20. However, FIG. 13 shows an embodiment wherein index scale holders 164 and 165 are employed to permit the index scales and stops to be used closer to the saw blade on either or both left and right sides and can be used for applications where only short cuts are desired, without the presence of an extension table at all.

The manner in which the miter saw 10 and its base 34 are moved to and from the job site has been described. The extension tables 72 and 74 are stored, protected and transported in case 166 shown in FIGS. 8 and 9.

Case 166 is rectangular in cross section and has a double L-shaped web 168 extending between its sides. The main part of the case is of uniform cross section so that it may be extruded. If desired, it may be extruded in several pieces and later joined. End caps 170 and 172 are provided to protect the contents. Cavities 174 and 176 are each sized and shaped to receive one of the extension tables with the stop attached, as shown in dashed lines in FIG. 9. Since the extension tables are designed with their lower supports foldable into the confines of the channel space of the table, the tables can be readily inserted into and removed from the case 166. While ensconced therein, they are well protected. In this way, an extension table apparatus for a miter saw is provided. The apparatus is protected during storage and transit and is easily erected at the job site to provide accurate cuts. The apparatus is also convenient to disassemble for storage or removal.

This invention has been described in its presently contemplated best mode, and it is clear that it is susceptible to numerous modifications, modes and embodiments within the ability of those skilled in the art and without the exercise of the inventive faculty. Accordingly, the scope of this invention is defined by the scope of the following claims.