GB2459362A

GB2459362A - Mitre saw with variable angle fence

Info

Publication number: GB2459362A
Application number: GB0906530A
Authority: GB
Inventors: Richard J Heavel; Robert S Gehret; Craig Alan Schell
Original assignee: Black and Decker Inc
Current assignee: Black and Decker Inc
Priority date: 2008-04-22
Filing date: 2009-04-16
Publication date: 2009-10-28
Also published as: GB0906530D0

Abstract

A mitre saw 50 comprises a table 56 defining a generally horizontal planar surface for supporting a workpiece; a saw mounted above the table; and a fence 55 attached to the table having a generally planar surface for resting a workpiece against. The planar surface associated with the table, and the planar surface 128 defined by the fence, can define an angle that is substantially not a 90 ° angle. An adjustable crown stop 140 may be attached to the fence. An adjusting mechanism 148, 150 may be provided on the fence, which permits the fence to adjust to different positions such that the planar surfaces associated with the fence and table can be adjusted to achieve a variety of angles. Preferably, the saw comprises a lower fence portion 130 attached to the table, which has a generally planar surface perpendicular to the table. The fence may include a cut-out portion (162, fig 5) that permits a worker to urge the workpiece against the fence.

Description

APPARATUS FOR A MITER SAW

The present invention relates generally to a support apparatus for supporting a workpiece being worked on by a power tool. More particularly, the present invention relates to a fence portion of a miter saw.

Tools such as miter saws and other power tools incorporate structures in order to orient and support a workpiece that is being worked on by the tool. One popular type of workpiece worked on by miter saws is crown molding. Because crown molding is used for decorative purposes, it is desirable to have a clean and precise cut made on the crown molding. Further, crown molding, when installed, will form joints with walls and/or other pieces of crown molding so it is desirable for the cuts to be precise so that the joints do not have gaps but rather are a flush fit.

There are two popular methods of using a miter saw to cut crown molding. In the first method, the crown molding is laid flat on the table portion of the miter saw.

The saw is capable of being simultaneously beveled and mitered to perform a compound miter to achieve the desired cut.

The second method is to place the crown molding in a "nested" orientation (i.e. leaning diagonally against the fence). This nested orientation can mimic the actual installed orientation of the molding and places the wall contact portion of the molding against the fence and the ceiling contact portion against the table. Some proponents of this method claim that it is more intuitive for a user to make adjustments to the cut when molding has to be installed in out of square conditions (where the walls upon which the molding is to be installed may not be square). Another aspect of this method is that cut quality may be improved because the blade enters the cut on the finished face of the molding rather than exiting out of the finished face of the molding.

Entering the cut at the finished face of the molding can improve cut quality on the finished side of the molding.

Occasionally crown stops are used to facilitate cutting crown molding in the nested orientation. Crown stops provide a surface to rest the front surface of the crown molding against. Crown stops are typically integrated into a miter saw table to help stabilize the workpiece. The location of a crown molding stop may be set depending on the size of the crown molding being cut. Because the surfaces of the crown molding in contact with the fence and table are small, it can be difficult to find the right position when setting up the crown stop position. Trying to set up the location of a crown stop by feel, guess, or trial and error can be inaccurate and difficult to repeat. This may result in inaccurate miter cuts which can result in gaps or poor fits in the corners of finished crown molding. Further, this method of holding the material can make the material unstable, hard to adjust, uncomfortable and difficult to hold securely during a cut. Not holding the material securely during the cut can degrade the quality of the cut, both aesthetically and in precisely locating the cut.

Another characteristic of typical miter saw designs is that many have their dimensions optimized for vertically or horizontally oriented workpiece cutting capacity. Maximizing nested oriented capacity it typically not considered in many miter saw designs.

Thus, it would be desirable to have a method and apparatus that can assist orienting and stabilizing crown molding in a nested or diagonal position with respect to the horizontal table and vertical surface of a typical fence. Such a device and method would be useful to stabilize the crown molding and place it in a repeatable position where it can be secured for cutting. It may also be desirable to have a miter saw capable of cutting larger crown molding in a nested orientation.

The foregoing needs are met, to a great extent, by the present invention, wherein in one aspect a method or apparatus is provided where crown molding is oriented and secured for cutting in a nested position in a repeatable way.

In accordance with one embodiment of the present invention, a miter saw is provided. The miter saw includes: a table defining a generally horizontal planar surface for supporting a workpiece; a saw mounted above the table; and a fence attached to the table having a generally planar surface for resting a workpiece against where the planar surface associated with the table and the planar surface defined by the fence define an angle that is substantially not a 90° angle.

In accordance with another embodiment of the present invention, a fence for a miter saw is provided. The fence includes: a body; a first connecting portion configured to connect to a miter saw to secure the body to the miter saw; a substantially planar surface defined by the body configured to rest a workpiece against when the body is connected to the miter saw, the planar surface configured to achieve a position at an angle substantially different than 90° with respect to a generally flat planar surface of a table of the miter saw when the body is connected to the miter saw; and a second connecting portion configured to connect a crown stop to the body.

In accordance with yet another embodiment of the present invention, a fence for securing a workpiece to a miter saw is provided. The fence includes: means for defining a generally planar surface at an angle other than 90° with respect to a table associated with the miter saw; means for providing a stop for a workpiece to rest against when resting on the generally planar surface; and means for attaching the means for defining the generally planar surface to the miter saw.

In accordance with still another embodiment of the present invention, a method of providing an angled surface to place a workpiece is provided. The method includes: attaching a fence to a table portion of a miter saw wherein the fence provides a substantially flat surface at an angle substantially different than 90° with respect to a flat workpiece supporting surface associated with the table; and attaching an adjustable crown stop to the fence.

There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

FIG. 1 is a perspective view illustrating a miter saw that may be equipped with a fence in accordance with the invention.

FIG. 2 is a perspective view of another type of miter saw that may be equipped with a fence in accordance with the present invention.

FIG. 3 is a perspective view taken from a different angle of the saw illustrated in FIG. 1.

FIG. 4 is a perspective view of a miter saw in accordance with an embodiment of the present invention.

FIG. 5 is a partial perspective view of a user holding a workpiece against a fence in accordance with an embodiment of the invention.

FIG. 6 is a perspective view of a user securing a workpiece against a fence in accordance with an embodiment of the invention.

FIG. 7 is a side view illustrating a workpiece set against a fence and a crown stop in accordance with an embodiment of the invention.

FIG. 8 is a side view illustrating a plane defined by a fence in accordance with the invention.

FIG. 9 is a perspective exploded view of a miter saw in accordance with an embodiment of the invention.

FIG. 10 is a side view of a miter saw with a fence in a second position in accordance with an embodiment of the invention.

FIG. 11 is a side view of a miter saw having a fence in accordance with another embodiment of the invention.

FIG. 12 is a side view of a miter saw in accordance with an embodiment of the invention and further illustrating different dimensions of workpieces that can be worked on in some embodiments of the invention.

FIG. 13 is a perspective view of an adjustable fence in accordance with one embodiment of the invention.

FIG. 14 is a perspective view of an adjustable fence in accordance with the invention where the fence has been adjusted to an approximately 90° angle.

FIG. 15 is a perspective rear view of an adjustable fence in accordance with an embodiment of the invention.

The invention will now be described with reference to the drawing figures, in which like reference characters refer to like parts throughout. An embodiment in accordance with the present invention provides a miter saw 50. A miter saw 50 includes a frame 52. The frame 52 has bench mounting holes 54. The bench mounting holes 54 assist in mounting the miter saw 50 to a work bench or table where bolts or screws can be extended through the bench mounting holes 54 to secure the miter saw 50 to the bench or table.

The miter saw 50 also has a fence 55 located on a table 56. The table 56 has a relatively flat portion upon which a workpiece can be set for being cut by the miter saw 50. The fence 55 defines a generally vertical surface 53 while the table 56 defines a generally horizontal surface 59. The two surfaces 53, 59 are useful for locating a workpiece for cutting.

The fence 55 has a fence adjustment knob 57 which can be loosened to adjust the fence along a horizontal position. Once the fence 55 is in a desired position the fence adjustment knob 57 can be tightened to secure the fence 55 in the desired position.

The table 56 includes a kerf plate 58. The kerf plate 58 includes or defines a slot 60. The slot 60 permits the saw blade to extend below the horizontal surface 59 of the table 56 without damaging the blade. The table 56 includes a stationary part 61 of the table 56 located on the outer periphery of the table 56 and is fixed with respect to the frame 52. The table 56 also includes a rotating part 63 of the table 56 that can be rotated with respect to the frame 52 as will be described in more detail below.

A miter lock handle 62 is mounted to the miter arm 65 on the rotating part 63 of the table 56. The miter lock handle 62 and miter latch button 64 can be actuated to unlock the miter arm 65 so that the miter arm 65 can be rotated to a desired position.

A miter latch override 66 is also provided on the miter arm 65. The miter latch override 66 allows the miter arm 65 to easily move past the common stop angles which may have detents 70 associated with them.

A miter scale 68 is located on the frame 52 and may be useful in selecting a position to rotate the miter arm 65. The miter scale 68, according to some embodiments of the invention, may have detents 70 which will allow the miter arm 65 to stop and "click" into place at various positions (often at common stop angles) along the miter scale 68.

As shown in FIG. 1 some embodiments of the invention include a miter saw 50 that is included with a blade wrench 72. Some embodiments of the miter saw 50 may also include a lockdown pin 74 and a bevel scale 76. The bevel scale 76 may be useful in allowing a user to determine a position to adjust the miter saw 50 when selecting a bevel angle. Bevel latch levers 78 and a bevel lock handle 82 can be articulated to allow the circular saw 83 to be beveled. In some embodiments of the invention, the circular saw 83 may be beveled 48 degrees left or right. The circular saw 83 may include two bevel latch levers 78, one on either side of the rear support housing 81.

In some embodiments of the invention, only one of the bevel latch levers 78 needs to be moved to bevel the circular saw 83 in either direction. The bevel lock handle 82 is on top of the rear support housing 81. In some embodiments of the invention, to bevel the circular saw 83 the bevel lock handle 82 is loosened and one of the bevel latch levers 78 may be lifted approximately 45 degrees and then the circular saw 83 may be beveled to the desired angle as indicated on the bevel scale 76. The bevel lock handle 82 is then locked in place to lock the saw 83 in place. The bevel latch levers 78 may be lifted vertically to override any detents at common stop angles located along the bevel scale 76. A rail lock knob 84 may also be located on the rear support housing 81 along with a rail set screw adjustment 86.

The circular saw 83 may include a motor housing 88, motor cap 80, and a lifting handle 90 for lifting the entire miter saw 50. An operating handle 92 is provided to permit just the circular saw 83 portion of the miter saw 50 to be raised and lowered in order to make miter cuts. The actual cutting blade itself may be protected by a saw blade housing 94 and a saw blade guard 96.

Other embodiments of the invention may include miter saws 50 that may have a slightly different lay out. For example, a second miter saw 50 is shown in FIG. 2. In the miter saw 50 illustrated in FIG. 2, a bevel scale 98 is located under the circular saw 83 and includes a bevel scale indicator 100. Also, the miter scale 102 is located on the frame 52 but instead of having a miter lock handle 62 as shown in FIG. 1, the miter saw 50 as shown in FIG. 2 includes a miter latch 104 and a miter clamp lock 106. It also has a fence clamp knob 108. The operating handle 92 includes a trigger switch 110 which may be common to many types of miter saws 50, not just those shown in the FIGS. Turning now to FIG. 3, the miter saw 50 illustrated in FIG. 1 is shown from a different angle to illustrate additional components. The operating handle 92 includes a trigger switch 110. A belt cover 112 is also illustrated. The circular saw 83 is mounted upon rails 114 and includes a thumb screw 116 to allow adjustment along the rails 114. A grooving stop 118 is provided.

As shown in FIG. 3, the miter saw 50 includes bevel latch plates 120 and a dust duct 122 where, in optional embodiments of the invention, dust can be collected in order to assist in keeping a working area clear of sawdust.

A hand indention 124 is located in the frame 52 in order to provide a hand hold to assist in moving the frame 52 to a desired position upon a table or workbench prior to being secured to the table or workbench. The hand indention 124 may also be a useful hand hold for whenever preparing to move the miter saw 50.

FIG. 4 illustrates a miter saw 50 in accordance with some embodiments of the invention. A miter saw 50 includes a fence 55. The fence 55 is made of two portions: a base portion 130 that is attached to the table 56. According to some embodiments of the invention, the base portion 130 is a standard base portion that may be available on a variety of saws which the remainder of the fence 55 may be attached.

In other embodiments in accordance with the invention the base portion 130 is different from what is readily available and is adapted for the purpose of securing a fence in accordance with the invention.

In FIG. 4 the fence 55 includes an angled plate 128. The angled plate 128 defines a front plane or surface 129 that is oriented at an angle with respect to the flat surface 59 defined by the table 56. In some embodiments of the invention, the angle between the angled plate 128 and the table 56 may be about 38 degrees, about 45 degrees, about 52 degrees, or any other angle substantially different from degrees. The angled plate 128 is adapted and configured to attach to the base portion 130 which in turn in attached to the table 56. Therefore, the angled plate 128 is attached to the table 56.

The angled plate 128 includes a hand-hold cutout portion 132 which will be explained in further detail below with respect to FIGS. 5 and 6. The angled plate 128 also includes a blade relief 134 cutout portion which is useful to avoid interference between the saw blade 167 and the angled plate 138 when the miter saw 50 is adjusted to extreme miter angles.

Some embodiments of the invention as shown in FIG. 4 may also include a crown stop relief 136 section that is dimensioned to allow the crown stop 140 to move through and break a plane defined by the front surface 129 of the angled plate 128 and will be discussed in more detail below. The crown stop 140 includes a vertical portion 142. The vertical portion of the crown stop 140 helps secure a workpiece in position as will be discussed further below. The crown stop 140 also includes a foot portion 144 which, in some embodiments of the invention, may rest against the table 56. The crown stop 140 also includes a slot 146 through which a fastener 148 passes through.

Awing nut 150 is attached to the fastener 148. The crown stop 140 attaches to the angled plate 128 via the fastener 148. The operator can loosen and tighten the fastener by turning the wing nut 150 to loosen the fastener 148 in order to allow the vertical portion 142 of the crown stop 140 to slide toward or away from the angled plate 128. Once the vertical portion 142 of the crown stop 140 has achieved a desired position the user will tighten the wing nut 150 which will cause the fastener 148 to screw into the angled plate 128 and secure the crown stop 140 to the desired position. The length of travel of the crown stop 140 may be determined by the length of the slot 146.

According to some embodiments of the invention, a mirror image fence portion 152 may be located on the miter saw 50 opposite the side shown and described herein. According to some embodiments of the invention, the opposite side fence portion 152 may be a mirror image to the fence 55 shown and described with respect to FIG. 4, or it may be slightly altered according to individual needs of a particular application.

FIGS. 5 and 6 illustrate using a fence 55 in accordance with an embodiment of the invention to secure various sizes of crown molding. For example, in FIG. 5 a relatively short workpiece 154 with respect to the height of the fence 55, is illustrated laying on the angled plate 128 and resting on the table 56. The relatively short workpiece 154 is also leaning against the vertical portion 142 of the crown stop 140.

A user's hand 158 supports the workpiece 154 against both the angled plate 128 and the table 56. The user places the hand 158 in the hand hold cutout 132 of the angled plate 128. The hand hold cutout 132 is particularly useful in order to allow the user to secure relatively short pieces of trim 154 to the angled plate 128.

In embodiments where no hand hold cutout 132 appears on the fence 55, the user may be limited to larger trim 154 so that it may be secured with the user's hand 158 because the user's thumb 160 and fingers 162 may not be long enough to secure a short piece of trim 154. However, as illustrated by FIG. 5, angled plates 128 equipped with a hand hold cutout 132 allow the user's hand 158 to grip shorter pieces of trim 154 as illustrated. The user's thumb 160 urges the trim 154 against the angled plate 128 and may, in some embodiments, also urge it against the table 56.

Meanwhile, the user's fingers 162 provide pressure against the back part of the angled plate 128 so that the user's hand 158 acts as a clamp to clamp the trim 154 to the angled plate 128.

The crown stop 140 is adjusted to help secure the trim 154 at a desired location along the angled plate 128. FIG. 6 illustrates how a relatively tall piece of trim 156 with respect to the angled plate 128 can be secured to the angled plate 128 and/or table 56 by a user's hand 158. Because the relatively tall piece of trim 156 sits higher upon the angled plate 128 then that shown in FIG. 5, the user's hand 158 sits higher in the hand hold cutout 132 as shown in FIG. 5. However, the securing of the relatively tall piece of trim 156 to the angled plate 128 and/or table 56, is done similar enough to that shown and described with respect to FIG. 5. The user places his hand 158 into the hand hold cutout 132 onto the piece of trim 156. The thumb 160 exerts pressure against the trim 156 to urge the trim 156 against the angled plate 128. The user's fingers 162 urge against the back portion of the angled plate 128 to hold the trim 156 against the plate 128 in a clamping manner.

The crown stop 140 has been adjusted so that the trim 156 is at a desired location with respect to the plate 128. The vertical portion 142 of the crown stop 140 is resting against the bottom portion of the trim 156 to keep the trim 156 at the proper location with respect to the height of the angled plate 128.

In some embodiments of the invention, the crown molding 156 may be taller than the angled plate 128 as shown, for example, in FIG. 7. In such instances, a user may choose to place the hand 158 securing the trim 156 to the angled plate 128 at a place along the angled plate 128 other than in the hand hold cutout 132 so that the user's fingers 162 can still contact the back of the angled plate 128 and so that the trim 156 can be held in a clamping manner 128 by the fingers 162 and thumb 160 applying opposing pressure to the workpiece 156 and the angled plate 128.

FIG. 7 is a side view of a saw 50 in accordance with one embodiment of the invention. A large piece of crown molding 164 is set upon the angled plate 128 and held in place from sliding down the angled plate 128 by the vertical portion 142 of the crown stop 140. The crown stop 140 has been adjusted so that the vertical portion 142 of the crown stop 140 is in the desired location in order to hold the crown molding 164 at a desired location. According to the some embodiments in accordance with the invention, a desired location for the crown molding 164 is one where the back flat portion of the crown molding 164 lays flat against the angled plate 128 and the crown molding 164 also sits on the flat surface 59 of the table 56.

The area defined by the vertical portion 142 of the crown stop 140 and the top flat surface 59 of the table 56 and the angled plate 128 is sometimes referred to as a nest 166. The size of the nest 166 can be adjusted by adjusting the crown stop 140.

In the embodiment shown in FIG. 7, the crown stop 140 can be adjusted by loosening the wing nut 150 and moving the crown stop 140 to a desired position and then tightening the wing nut 150. The range in which the crown stop 140 may be adjusted is determined by the geometry of the slot 146 in the embodiment shown in FIG. 7. In other embodiments in accordance with the invention, the crown stop 140 may be adjustable in a variety of suitable ways.

It will be appreciated by one skilled in the art that the crown molding 164 illustrated in FIG. 7 is taller than the angled plate 128 and extends past the angled plate 128. The saw 50 shown in FIG. 7 is capable of cutting the entire crown molding 164 in a single operation because the crown molding 164 does not extend beyond the saw blade 167.

FIG. 8 illustrates a saw 50 where the crown stop 140 can be moved to a position where it does not at all interact with the workpiece 154, 156 or crown molding 164. As shown in FIG. 8, the crown stop 140 has been slid to a position where the vertical portion 142 of the crown stop 140 is retreated to a position behind the angled plate 128. The line indicated by reference number 168 shows a line or plane defined by angled plate 128. While the line 168 is extended beyond the top surface 59 of the table 56 a workpiece 154, 156 or crown molding 164 would not extend beyond the top surface 59 of the table 56 but would rest on the table 56. The line 168 indicates where a workpiece 154,156 or piece of trim 164 would be located if resting flat against the angled plate 128. As indicated in FIG. 8, the vertical portion 142 of the crown stop 140 is moved so that it is on the back side of the line 168. This position is useful for when a user does not want to use a crown stop 140 but doesn't necessarily want to remove the crown stop 140 from the saw 50. The user may want to leave the crown stop 140 attached to the saw 50 so that the crown stop 140 doesn't get lost or clutter the work area.

It is noted that the vertical portion 142 extends into the crown stop relief 136 of the vertical plate 128. However, in other embodiments of the invention, the vertical plate 128 may not have a crown stop relief portion 134 but the crown stop 140 may still achieve a position where the crown stop 140 does not engage a workpiece. For example, the vertical portion 142 may fit under the vertical plate 128.

As shown in FIG. 8, the foot portion 144 of the crown stop 140 also is on the back side of the line 168 and so according to some embodiments of the invention the crown stop 140 may achieve a position where no part of the crown stop 140 engages a workpiece.

FIG. 9 is a exploded perspective view of the fence 55 and miter saw 50. The fence 55 attaches to the miter saw 50 via the base portion 130. The base portion 130 is attached to the frame 52 of the miter saw 50. The base portion 130 attaches to the fence 55 by a tongue and groove type connection. The base portion 130 defines a groove 169. A tongue 171 located on the fence 55 slips into the groove 169 allowing the fence 55 to be adjusted laterally with respect to the grove 169. Holes in the back of the base portion 130 have interior threads. Fasteners 172 terminated by wing nuts or fasteners handles 174 may be screwed into the holes in the base portion 130 SO that the threaded fasteners 172 can urge against the back portion of the tongue 171 to hold the fence 55 in place. Other ways of attaching a fence 55 to the saw 50 may be used in accordance with the invention.

Holes 170 located on the base portion 130 may be used to attach other types of fences 55. The holes 170 are an optional feature and are not necessary for practicing the invention.

In the embodiment shown in FIG. 9, the crown stop 140 is attached to the fence even when the fence 55 is removed from the saw 50. The wing nut 150 that is used to tighten the fastener 148 also may act to keep the crown stop 140 in position.

The crown stop 140 may be locked in position and stay locked in position even when the fence 55 is attached or removed from the saw 50. Therefore, it is not required that whenever the fence 55 be moved or removed from the saw 50 that the crown stop 140 needs to be repositioned. One who is skilled in the art will readily see that, alternatively, the crown stop 140 can be attached to the frame 52, rather than the fence 55.

In some embodiments of the invention, the fasteners 172 may extend in the holes in the fence 55 to secure the fence 55 in position to the base portion 130 or in other embodiments the ends of the fasteners 172 may simply urge tightly against the tongue 171 to keep the fence 55 secured to the base portion 130 in a friction-fit type manner.

FIG. 10 illustrates another embodiment in accordance with the invention where the angled plate 128 is hinged and can be moved to a second position. As shown in FIG. 10, a hinge pin 178 provides a means to allow the angled plate 128 to pivot or rotate about the hinge pin 178 from a first position similar to that shown in FIG. 7 or 8 to a second position shown in FIG. 10. In the second position shown in FIG. 10, the angled plate 128 is rotated so that its front surface 129 is located behind the flat surface 180 of the base portion 130. The flat surface 180 of the base portion 130 is located approximately perpendicular to the flat surface 59 of the table 56.

On the back side of the angled plate 128 is a flat surface 182 that when the angled plate 128 is located to the second position, the flat surface 182 lines up to be substantially coplanar to the flat surface 180 of the base portion 130. Together the flat surface 182 of the back side of the angled plate 128 and the flat surface 180 of the base portion 130 comprise a fence 55 that is substantially perpendicular to the flat surface 59 of the table 56. Thus, in the embodiment illustrated in FIG. 10, an operator has the option of using an angled fence 55 by having the angled plate 128 flip down to a position similar to that shown in FIGS. 6 and 7 or a substantially perpendicular fence 55 when the angled plate 128 is flipped back to a second position as shown in FIG. 10.

In other embodiments of the invention, the angled plate 128 can be adjusted to a variety of positions between a first and second position so that the flat front surface 129 of the angled plate 128 can be at a variety of angles with respect to the flat surface 59 of the table 56.

The crown stop 140 has been removed in FIG. 10 to better illustrate aspects of the miter saw 50 discussed in FIG. 10. However, in some embodiments of the invention, the crown stop 140 may be removed when flipping angled plate 128 to the flipped up or back position. In other embodiments of the invention, the crown stop may be used in conjunction with the flat surfaces 180 and 182 associated with the back part 182 of the angled plate 128 and the base portion 130.

FIG. 11 is a side view of another embodiment in accordance with the invention illustrating a saw 50 where the fence 55 includes an angled plate 128 which has located at the bottom of it a vertical portion 184. The vertical portion 184 defines a vertical surface 185. The vertical surface 185 defined by the vertical portion 184 intersects with the top surface 59 of the table 56 at a substantially right angle.

However, the vertical portion 184 may not actually contact the top surface 59 of the

table 56.

The crown stop 140 is dimensioned so it can be adjusted so that the vertical portion 142 of the crown stop 140 is located behind the surfaces 129 and 185. So configured, the crown stop 140 can be adjusted to be used or put out of use according to the desires of an operator similar to as described above with respect to FIG. 8. The crown stop 140 may be attached to the angled plate 128 as described above. In order for the vertical surface 142 of the crown stop 140 to retreat to the position shown in FIG. 11, the angled plate 128 and the vertical portion 184 may be equipped with a crown stop relief cutout 136 as described above. If a user desires to use the crown stop 140, the crown stop 140 can be adjusted along the slot 146 sO that the vertical portion 142 of the crown stop 140 can be placed in a desired position.

FIG. 12 is a side view of a saw 50 illustrating some comparisons of different workpieces 154 and 156 that can be worked depending on whether the fence 55 is equipped with an angled plate 128 or with a vertical surface 53 of a vertical type fence 55. As shown in FIG. 12, there are two pieces of crown molding 154 and 156 illustrated. They are superimposed on each other for comparison purposes. The piece of crown molding 154 shows the piece of crown molding butted against a vertical surface 53 and the table 56. Line 186 illustrates the length that a piece of crown molding 54 can be used when incorporating a fence 55 with a vertical surface 53. Crown molding piece 156 illustrates where an angled type fence 55 is used. Line 190 indicates an approximate amount of the crown molding 156 that is supported by an angled plate 128 when the angled plate 128 is being used. Line 188 indicates an approximate length of crown molding 156 that can be cut with a saw 50 incorporating an angle type fence 55 such as with an angled plate 128. By inspection, it is clear that saws equipped with angle type fences 55 can cut longer pieces of crown molding 156 then saws equipped with fences 55 defining vertical surfaces 53. The size of crown molding 156, 154 that the saw 50 is limited to cut is generally defined by the geometry of the saw 50.

Also shown in FIG. 12 are the fastener handles or wing nuts 174 attached to the fasteners 172 that are located in the holes 173 of the lower portion 130 of the fence 55. The fastener handles or wing nuts 174 and fasteners 172 are shown in an assembled position as opposed to an exploded position as shown in FIG. 9.

FIG. 13 illustrates an embodiment in accordance with the invention where the fence 55 has an angled plate 128 that is adjustable. An adjusting mechanism 192 includes a quadrant 194. The quadrant 194 is a curved plate containing a slot 196. A lock knob 198, which may be a wing nut as shown in FIGS. 13-15, actuates a lock fastener 200 (see FIG. 15). The lock knob 198 can be tightened to secure the angled plate 128 or loosened to permit the angled plate 128 to pivot.

The quadrant 194, in some embodiments of the invention, can include a scale 202 which can enable a user to determine the approximate angle of the angled plate 128 with respect to a table surface upon which the fence 55 is mounted. The quadrant 194 may be attached to the angled plate 128 via fasteners 204.

The angled plate 128 pivots on a pivot pin 208. The angled plate 128 may be equipped with a lug 206 having a pivot pin hole 210. The pivot pin 208 fits within the pivot pin hole 210 connecting the angled plate 128 to the non-pivoting part 212 of the fence 55. The pivoting action of the angled plate 128 provides a moveable surface 129 upon which crown molding or other workpieces may rest and be secured to as described above.

The non-pivoting part 212 of the fence 55 is attached to a base portion 130 of the fence 55. The base portion 130 of the fence 55 may be attached to a table 56 as described above.

In accordance with some embodiments of the invention, the amount that the angled plate 128 can pivot or be adjusted to is defined by the geometry of the slot 196. According to some embodiments of the invention, in order to adjust the angled plate 128, the lock knob 198 can be loosened and the angled plate 128 can be pivoted by a user to a desired position.

The position of the angled plate 128 can be confirmed by the user by viewing the scale 202 with respect to an indicator or pointer 213 attached to the non-pivoting part 212 of the fence 55. The indicator 213 will "point" to a place along the scale 202 indicating a relative position between the angled plate 128 and the non-pivoting part 212 of the fence 55. In some embodiments, the indicator 213 is stationary as it is attached to the non-pivoting part 212 of the fence 55. The quadrant 194 with the scale 202 on it may rotate under part of the indicator 213 as the angled fence 128 is rotated. The scale 202 is calibrated with the indicator 213 to have the indicator 213 point at a value along the scale 202 that will indicate to a user the relative position of the angled plate 128 with respect to the table 56. The scale 202 may provide a reading in degrees away from either or both of a horizontal (e.g., the generally flat table surface) or vertical (e.g., the surface of the angled plate 128 when it is at a 90° angle with respect to the flat table surface) datum. Once the angled plate 128 has been adjusted to the desired position, the lock knob 198 can be tightened, thus tightening the angled plate 128 in position.

FIG. 14 illustrates an angled plated 128 that has been adjusted to an approximate vertical position. When the fence 55 shown in FIG. 14 is mounted upon a table then the front face 129 of the angled plate 128 would be approximately 90° with respect to a table. According to some embodiments of the invention, the slot 196 would be sized in order to permit the angled plate 128 to achieve an approximate 90° angle as shown in FIG. 14 to a smaller angle as shown in FIGS. 13 and 15 including a 38° angIe with respect to a table and angles in-between.

FIG. 15 illustrates a fence 55 having an adjustable plate 128 from a rear view.

As shown in FIG. 15, the angled plate 128 includes a lug 206 having a pivot pin hole 210 in which there is a pivot pin 208. The pivot pin 208 also extends into a lug 214 located on the stationary part 212 of the fence 55.

According to some embodiments of the invention, the fence 55 can be equipped with a detent mechanism 216. The detent mechanism can provide stops for the angled plate 128 at various angles. For example, detents can exist where the plate 128 is at 90°, 52°, 45°, and 38° with respect to a table. Other detent angles can also be selected by one skilled in the art. The user can override the detents to have the angled plate 128 achieve other angles as desired.

Suitable detent mechanisms 216 can incorporate a variety of mechanisms that will be suitable for providing stops for the angled plate 128. For example, the detent mechanism 216 can include a spring loaded ball urging against a back portion of the quadrant 194. The spring loaded ball could roll along the quadrant 194 adjacent to the slot 196. Along the path of the ball at selected angles, cut out portions could be made in the quadrant 194 so the spring loaded ball would fit into the cut out or detented portions of the quadrant 194 causing the angled plate 128 to stop at those various angles. At one of these steps, the user could then tighten the lock knob 198 in order to keep the angled plate 128 at that desired angle.

If a particular stop angle was not desired by the user, then additional pivoting force on the angled plate 128 could cause the ball to move against its spring loading and move out of the cut out. In this manner the user could override the detent mechanism 216. Of course, this sort of detent mechanism 216 has been explained as an example and other suitable detent mechanisms could also be used in accordance with the invention.

The many features and advantages of the invention are apparent from the detailed specification, and thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

Claims

CLAIMS1. A miter saw comprising: a table defining a generally horizontal planar surface for supporting a a saw located above the table; and a fence attached to the table having a generally planar surface for resting a workpiece against where the planar surface associated with the table and the planar surface defined by the fence define an angle that is substantially not a 90° angle.
2. The miter saw of claim 1, further comprising a cut out portion in the fence dimensioned and located to permit a worker to urge a workpiece against the fence with the users thumb and extend the workers fingers through the cut out portion an engage a back portion of the fence to hold the workpiece against the fence.
3. The miter saw of claim 1, wherein the angle defined by the planar surfaces defined by the fence and table is about a 450, 52°, or 38° angle.
4. The miter saw of claim 1, further comprising an adjusting mechanism on the fence configured to permit the fence to adjust to different positions such that the planar surfaces associated with the fence and table can be adjusted to achieve a varietyofangles.
5. The miter saw of claim 4, further comprising a locking mechanism operatively connected to the fence to selectively lock the fence in a position.
6. The miter saw of claim 4, further comprising a detent system configured to selectively lock the fence at certain angles with respect to the table.
7. The miter saw of claim 6, wherein the detent system selectively locks the fence such that the planar surfaces of the fence and table are at least one of about 52°, 38° and 45° angles with respect to each other.
8. The miter saw of claim 1, further comprising a crown stop located at least in part above the table.
9. The miter saw of claim 8, wherein the crown stop is attached to the fence.
10. The miter saw of claim 8, further wherein the crown stop is adjustable to permit the crown stop to move to different positions including a position on a side opposite of the generally planar surface associated with the fence such that the crown stop is for resting a workpiece against.
11. The miter saw of claim 1, further comprising: an attaching mechanism configured to selectively attach the fence to the table; an adjustable crown stop attached to the fence; and a locking mechanism configured to lock the adjustable crown stop to the fence in a particular position with respect to the fence, wherein the crown stop is lockable in a particular position with respect to the fence, when the fence is detached from the table.
12. The miter saw of claim 1, further comprising a lower fence portion attached to the table, the lower fence portion providing a mount for the fence to attach to the table, the lower fence portion defining a generally planar surface substantially perpendicular with respect to the generally planar surface associated with the table, wherein the generally planer surface defined by the fence extends through the generally planar surface defined by the lower fence portion, whereby a workpiece resting against the generally planar surface defined by the fence may extend in front of and behind generally planar surface defined by the lower fence portion.
13. The miter saw of claim 1, further comprising a second generally planar surface defined by the fence wherein the fence is configured to move between two positions, a first position where the generally planar surface defined by the fence is orientated at a position with respect with the planar surface defined by the table at an angle that is substantially not a 90° angle and a second position where the second generally planar surface is at about a 90° angle with respect to the planar surface defined bythe table.
14. The miter saw of claim 13, wherein the planar surface defined by the table is located, at least in part, behind the second generally planar surface when the fence is in the second position.
15. The miter saw of claim 1, further comprising a second generally planar surface defined by the fence for resting a workpiece against that is at a substantially 90° with the planar surface defined by the table.
16. A fence for a miter saw comprising: a body; a first connecting portion configured to connect to a miter saw to secure the body to the miter saw; a substantially planar surface defined by the body configured to rest a workpiece against when the body is connected to the miter saw, the planar surface configured to achieve a position at an angle substantially different than 90° with respect to a planar surface of a table of the miter saw when the body is connected to the miter saw; and a second connecting portion configured to connect a crown stop to the body.
17. The fence of claim 16, further comprising: an adjusting mechanism configured to permit the planar surface defined by the body to achieve a variety of positions when the body is connected to a table of a miter saw; and a locking mechanism configured to selectively secure the body in a position, wherein the positions include the planar surface defined by the body to achieve a range of about 90° to 38° with respect to the generally planar surface associatedwith the table.
18. The fence of claim 16, further comprising a crown stop adjustably attached to the fence having a range sufficient to permit a vertical portion of the crown stop to extend far enough away from the fence to permit a workpiece engaging the vertical portion of the crown stop to lay flat against the planar surface defined by the body at one extreme and to have the vertical portion of the crown fence retreat toward and be located behind the planar surface defined by the body at the other extreme.
19. The fence of claim 16, further comprising a cut out portion in the fence dimensioned and located to permit a worker to urge a workpiece against the fence with the users thumb and extend the workers fingers through the cut out portion an engage a back portion of the fence to hold the workpiece against the fence.
20. A fence for securing a workpiece to a miter saw comprising: means for defining a generally planar surface at an angle other than 90° with respect to a table associated with the miter saw; means for providing a stop for a workpiece to butt against when resting on the generally planar surface; and means for attaching the means for defining the generally planar surface to the miter saw.
21. A method of providing an angled surface to place a workpiece comprising: attaching a fence to a table portion of a miter saw wherein the fence provides a substantially flat surface at an angle substantially different than 90° with respect to a flat workpiece supporting surface associated with the table; and attaching an adjustable crown stop to the fence.