Folding sawhorse

[0001] This application claims priority to and is a continuation-in-part of U.S. application Ser. No. 13/248,005, filed Sep. 28, 2011 now abandoned and titled “Folding Sawhorse,” which is hereby incorporated by reference in its entirety. U.S. application Ser. No. 13/248,005 claims the benefit of U.S. application Ser. No. 13/156,326, which is a continuation of U.S. application Ser. No. 10/908,388, which applications are also hereby incorporated by reference in their entirties.

[0002] The present invention relates to sawhorses, scaffolds and trestles. In particular, the present invention relates to sawhorses that are opened for use and folded to collapse for storage.

[0026] As used herein, the term “stabilizing surface” refers to any structure or component of a folding sawhorse adapted to be in physical contact with the ground or other surface while the sawhorse is in use.

[0027] As used herein, the term “stress bearing structures” refers to any structure which supports or resists a loads or stress, including, but not limited to, bending, tensile stress and compression.

[0028] Sawhorses are used as racks or trestles to support construction materials and other objects. With their wide base, sawhorses provide stable support for a work piece while being portable. Non-folding sawhorses, however, require a substantial amount of space for storage and transportation. To ameliorate this problem, sawhorses were designed to fold and collapse.

[0029] Unfortunately, many current folding sawhorses are unable to withstand sideways motion in the load they support. In particular, folding sawhorses with legs positioned on a common side are not in rigid contact with each other which results in the legs pivoting with respect to the upper central member of the sawhorse when the sawhorse is under load.

[0030] Other folding sawhorse designs require the of two sawhorses to support working materials or equipment in a horizontal position. While providing adequate support, the necessity of having two separate sawhorses is cumbersome and onerous.

[0031] Therefore, what is needed is a single folding sawhorse that easily unfolds and supports a variety of working materials. What is further needed is a folding sawhorse that is capable of supporting a bad while withstanding the effects of lateral movement of the particular bad. Finally, what is needed is a folding sawhorse that is constructed from lightweight materials.

[0032] The present invention is a folding sawhorse comprised of two pivotally connected frames containing a plurality of stress bearing structures on their inner surfaces and forming a 60 degree angle when locking in place by a locking shelf. The frame components are comprised of two parallel vertical members separated at a distance by an upper horizontal brace and parallel lower horizontal brace. A U-shaped bad bearing support is connected to the upper surface of the upper horizontal braces and provides four surfaces across which a load may be distributed when the folding sawhorse is in use. The trapezoidal locking shelf is pivotally connected to the lower horizontal braces and contains a central hinge, allowing the shelf to fold when the sawhorse is collapsed along its central vertical hinge.

[0033] For the purpose of promoting an understanding of the present invention, references are made in the text to exemplary embodiments of a folding sawhorse, only some of which are described herein. It should be understood that no limitations on the scope of the invention are intended by describing these exemplary embodiments. One of ordinary skill in the art will readily appreciate that alternate but functionally equivalent structures and materials may be used. The inclusion of additional elements may be deemed readily apparent and obvious to one of ordinary skill in the art. Specific elements disclosed herein are not to be interpreted as limiting, but rather as a basis for the claims and as a representative basis for teaching one of ordinary skill in the art to employ the present invention.

[0034] It should be understood that the drawings are not necessarily to scale; instead, emphasis has been placed upon illustrating the principles of the invention. In addition, in the embodiments depicted herein, like reference numerals in the various drawings refer to identical or near identical structural elements.

[0035] FIGS. 1-3 illustrate folding sawhorse 10 in the fully opened position. In the exemplary embodiment shown, folding sawhorse 10 is generally V-shaped with a first trestle frame 12 and a second trestle frame 14 connected to one another with a central hinge 16.

[0036] Frames 12 and 14 are generally rectangular having central rectangular apertures 80 and legs 40a, 40b and 52a, 52b projecting downward from frames 12 and 14, respectively. In the exemplary embodiment shown, legs 40a, 40b and 52a, 52b are integral with frames 12 and 14, respectively. However, in further exemplary embodiments, legs 40a, 40b and 52a, 52b may be separate physical components of folding sawhorse 10 which may be permanently or removably interconnected with frames 12 and 14.

[0037] As illustrated, legs 40a, 40b and 52a, 52b work together to create a three-point contact with the ground or other surface for while sawhorse 10 is in use. Legs 40a and 52a, closest to central hinge 16, act as a single stabilizing surface, while legs 40b and 52b, furthest from central hinge 16, act as distinct stabilizing surfaces.

[0038] Also illustrated in FIGS. 1-3 are the surfaces of frames 12 and 14. In the exemplary embodiments shown, frames 12 and 14 contain smooth outer surfaces while the inner surfaces contain a plurality of structural trusses, struts and other stress-bearing structures molded within frames 12 and 14.

[0039] As illustrated, there are three types of stress-bearing structures included on each of frames 12 and 14. Running vertically from legs 40a, 40b and 52a, 52b to the top of frames 12 and 14 are horizontal supports 90a, which are alternately aligned between vertical supports 90b. Horizontal supports 90a and vertical supports 90b spread and distribute force horizontally over legs 40a, 40b and 52a, 52b so that weight (when folding sawhorse 10 is in use) is evenly distributed on legs 40a, 40b and 52a, 52b. Frames 12 and 14 also contain diagonal braces 92a with vertical struts 92b running horizontally above the frame apertures 80. The diagonal braces 92a with vertical struts 92b work to distribute weight evenly across load bearing supports 42 and 54. Finally, the lower portions of frames 12 and 14 contain diamond-shaped support structures 94 which help evenly distribute weight from load bearing supports 42 and 54 and shelf 20 between legs 40a, 40b and 52a, 52b.

[0040] A center folding shelf 20 controls the opening and closing movements of frames 12 and 14. Shelf 20 is attached to a lower strut 22 on frame 12 and a lower strut 24 on frame 14. In particular, shelf 20 is interconnected with strut 22 with a shelf hinge 26 and with strut 24 with shelf hinge 28. Shelf 20 further includes a central shelf hinge 30 and is generally trapezoidal. Shelf 20 locks sawhorse 10 in an open stable position while also providing a surface upon which a user may place tools and parts associated with a particular job.

[0041] In the exemplary embodiment illustrated, shelf 20 contains a lip to prevent items from rolling on shelf 20. However, in other further embodiments, shelf 20 may omit lip. In still further exemplary embodiments, shelf 20 may contain apertures or compartments to accommodate specific tools or accessories commonly used in the art.

[0042] FIGS. 4-5 illustrate folding sawhorse 10 in closed position. In operation, sawhorse 10 is opened from a closed position (illustrated in FIGS. 4-5) by slightly spreading apart frames 12 and 14 to an unfolded working position (as illustrated in FIGS. 1-3). Sawhorse 10 remains in a locked open position without any additional latching mechanism until frames 12 and 14 are returned to a closed position by applying light upward pressure on central shelf hinge 30. Shelf 20 then roves upwardly, thereby causing frames 12 and 14 to pivot inwardly towards each other until frames 12 and 14 are in a closed position.

[0043] In the preferred embodiment, frame 12 includes a first vertical member 32 opposite and parallel to a second vertical member 34 having an upper horizontal brace 36 and a lower horizontal brace 38 orthogonally configured therebetween. A pair of parallel spaced apart legs 40a, 40b extends from and is integrally formed with lower horizontal brace 38. A load bearing support 42 is formed along the top edge of upper horizontal brace 36.

[0044] Similarly, frame 14 includes a first vertical member 44 opposite and parallel to a second vertical member 46 having an upper horizontal brace 48 and a lower horizontal brace 50 orthogonally configured therebetween. A pair of spaced apart legs 52a, 52b extends from and is integrally formed with lower horizontal brace 50. A bad bearing support 54 is formed along the top edge of upper horizontal brace 48.

[0045] The inner surfaces of vertical members 32, 34, 44 and 46 contain horizontal supports 90a and vertical supports 90b (not shown). Upper horizontal braces 36 and 48 contain diagonal braces 92a with vertical struts 92b (not shown). Lower horizontal braces 38 and 50 contain diamond-shaped supports 94.

[0046] In the exemplary embodiments shown in FIGS. 1-5, load bearing supports 42 and 54 are U-shaped, thereby forming a channel across the upper edges of horizontal braces 36 and 48, respectively. When folding sawhorse 10 is in use, an object placed across the top of folding sawhorse 10 will be in physical contact with the four upper surfaces (42a, 42b and 54a, 54b) of the U-shaped load bearing supports 42 and 54.

[0047] Frames 12 and 14 pivot about hinge axis 16 along vertical leg edge 18 parallel to legs 40a, 40b and 52a, 52b and perpendicular to braces 36, 38, 48 and 50. Trapezoidal shelf 20 includes a first side 56 interconnected via hinge 26 to lower horizontal brace 38 of frame 12, and a second side 58 interconnected via hinge 28 to lower horizontal brace 50 of frame 14.

[0048] In the open position, trapezoidal shelf 20 is perpendicular to central hinge 16 that interconnects frames 12 and 14, thereby resulting in a “V” shaped configuration between frames 12 and 14 connected at hinge 16. In a closed storage position, frame 12 is generally parallel to frame 14 with trapezoidal shelf 20 folded therebetween. In the open position, shelf 20 rigidly secures legs 40a, 40b and 52a, 52b in position so they do not move with respect to one another. The rigid positioning of legs 40a, 40b and 52a, 52b combined with central hinge 16 securing frame 12 to frame 14 prevents relative motion between the components of sawhorse 10, resulting in a rigid support structure designed to accommodate a substantial load.

[0049] In the exemplary embodiments shown, frames 12 and 14 have a length of 30 inches and a height of 31 inches. When locked in its open position, frames 12 and 14 create a 60 degree angle. Legs 40a, 40b and 52a, 52b are 4 inches wide by 1.75 inches deep, resulting in a surface area for each of 7 inches squared. Because legs 40a, 40b and 52a, 52b work together to create three stabilizing areas, the resulting stabilizing surfaces are 7 inches squared (for legs 40b and 52b) and 14 inches squared (for combined legs 40a and 52a).

[0050] While the above-dimensions are preferred, in further exemplary embodiments, frames 12 and 14 may have slightly variable dimensions. For example, frames 12 and 14 may be specifically manufactured for use with a certain material or weight. In some exemplary embodiments, the length and height of frames 12 and 14 may range between 25 and 35 inches. In most exemplary embodiments, frames 12 and 14 will have the same length and height.

[0051] Similarly, the 7-inches-squared surface area of legs 40a, 40b and 52a, 52b is preferred because a smaller surface area will not provide enough stability and it may be difficult to find a level surface to stabilize legs having a larger surface area. However, in further exemplary embodiments, the surface area of legs 40a, 40b and 52a, 52b may range from 5 to 10 inches squared.

[0052] In still further exemplary embodiments, frames 12 and 14 may create a different angle. For example, frames 12 and 14 may create an angle in the range of 50 to 70 degrees.

[0053] FIGS. 6-9 illustrate the separate components of frame 12, with frame 14 (not shown) being symmetrically formed. As previously described, load bearing support 42 is formed along top edge of upper horizontal brace 36. Central hinge 16 interconnects frame 12 with frame 14.

[0054] FIG. 7 clearly illustrates the different stress bearing structures integrally molded with frame 12. The inner surfaces of vertical members 32, 34, 44 and 46 contain horizontal supports 90a (not shown) with vertical supports 90b. Upper horizontal braces 36 and 48 contain diagonal braces 92a (not shown) with vertical struts 92b (not shown). Lower horizontal braces 38 and 50 contain diamond-shaped supports

[0055] FIGS. 14-17 illustrate the components of shelf side 56 of shelf 20. Central shelf hinge 30 connects side 56 to shelf side 58. Hinge 26 interconnects side 56 to frame 12. Similarly, as illustrated in FIGS. 18-21, central shelf hinge 30 connects side 56 to shelf side 58. Hinge 28 interconnects side 58 to frame 14. FIGS. 22 and 23 illustrate a tube member 60 which is part of hinge 16.

[0056] In the exemplary embodiments shown, hinges 30, 26 and 28 are created by a plurality of looped members 99 through which tube member 60 passes to form pivotal joints. As illustrated in FIGS. 22 and 23, tube member 60 is generally cylindrical having notched segments 62 alternated with smooth segments 64 and provides a surface around which frames 12 and 14 and shelf sides 56 and 58 may pivot to go from the open position to the closed position.

[0057] In the exemplary embodiments described, sawhorse 10 is manufactured from a lightweight plastic material. In further exemplary embodiments, however, sawhorse 10 may be manufactured from other materials, including wood. Similarly, shelf 20 is described in the exemplary embodiments as trapezoidal, but may be any other shape while still functioning as a locking mechanism between frame 12 and frame 14. Frames 12 and 14 may also be constructed as single continuous panels without separate vertical members and horizontal braces.