Technical field
This invention relates to a work bench. In particular, but not exclusively, this invention relates to a work bench comprising a frame for clamping a work-piece in a vertical orientation, a manually operated clamp and a benchtop clamp.
Background to the invention
Work benches are well-known and an example of such a bench is the Black and Decker WORKMATE bench (RTM). The bench is supported on a support frame which rests on the floor during operation. The bench itself comprises a vice having two clamping jaws or leaves which are movable relative to one another by a screw- thread arrangement. The screw-thread can be turned manually to reduce the distance between the jaws. In this manner, a work-piece placed between the jaws can be clamped firmly thereby leaving both operator's hands free to allow the operator to do work on the work-piece. For instance, the operator can clamp a piece of lumber and whilst it is held firm by the work bench the operator is free to saw the lumber. Such a work bench is described in US 3,615,087.
The reach of the work bench jaws, or the maximum distance to which the jaws can extend, is limited. As a result, the size of work-piece which the work bench can receive is limited. Thus, if the operator wishes to work on a relatively large work- piece, such as a door or board, then present work benches may not be practical, or
have sufficient extension for clamping or holding the work-piece firmly so that the operator can work on the work-piece.
Also, the distance between the jaws and the screw-thread arrangement for moving the jaws limits the size, or depth, of a work-piece which can be clamped by the vice. As a result, a work bench of this type is not able to hold a relatively large board in a vertical orientation with sufficient stability to allow the operator to do work on a portion of the board which is furthest from the vice in which it is clamped.
For example, it is often required to hold a door on an edge so that recesses or mortises can be cut for receiving a lock mechanism, or a hinge. Furthermore, it might be necessary to reduce the height or width of a door so that it properly fits into a door frame. This requires the door to be held such that its faces are vertical. As discussed above, it is possible to clamp a door in such a position using present work benches, but invariably the door is held with insufficient stability to allow the operator to work properly on the door. This problem is not limited to doors and other boardlike materials (such as plasterboard or chipboard sheets, for instance) having relatively large dimensions cannot be held sufficiently firmly by present clamp systems.
Various attempts have been made to solve the problem of how to provide adequate support to allow an operator to properly work on a door or board.
For instance, US 3,322,422 proposes a vice device for holding the door or the like to assist in hanging of the door and to facilitate fitting the door for an opening in which it
is to be placed as well as supporting of the door while cutting mortises or attaching hinges. The vice is actuated by the weight of the door, or article, held in the vice.
Also, US 5,082,038 proposes a door fabrication station for sawing and mounting hardware on a door comprising an upper door support frame and a leg assembly extending below the support frame to provide a surface on which the door fabrication station is supported. A lower support can support a door in a generally vertical position.
Likewise, US 5,113,920 is directed to a work bench, particularly for doors. Supports in the legs of the work bench allow a door to be supported in the vertical position.
It can take some time for the operator to open the work bench's jaws, place a work- piece between the jaws, and tighten the jaws to hold firmly the work-piece before conducting work thereon. Known work benches usually require the operator to twist handles attached to the screw-thread so that the jaws are moved relative to one another.
A foot-operated clamp or vice systems allows the operator to place and firmly clamp a work-piece in a vice quickly. Being able to manually operate the vice by a foot pedal (or the like) has the advantage that both the operator's hands are free to manipulate the work-piece whilst it is being clamped in place by the application of a clamping force applied by the user's foot. Also, the operator can remove one work- piece from the vice using one hand and replacing it with another workτpiece using his other hand.
Various foot operated vice systems are known. For instance, WO 90/02027 describes a work bench capable of clamping work-pieces. A clamping member is provided to clamp a work-piece between the clamp the work bench. A foot treadle is pivotally mounted on a support structure and a linkage interlinks the foot treadle with the clamping member.
Furthermore, US 6,502,810, US 5,351,944, GB 2150880 and GB 579207 each describe a foot operated clamping device which causes a clamping member to bear down on a substantially horizontal work surface when a pedal is pressed by the operator's foot.
EP 1003629, WO 90/14501 and EP 064883 each describe foot operated clamping devices. The operation of a pedal causes a vice's jaws to come together, thereby allowing the user to' hold a work-piece as it is clamped in the vice. The jaws are operated in the horizontal plane.
Alternative clamping arrangements which incorporate a wedge shaped clamping member can be used to allow the operator to quickly and firmly clamp a work-piece in such a way that the operator has access to the top surface of the work-piece whilst it is clamped. Such an arrangement is described in DE 8714162U. A hammer is usually required to provide a physical "knock" to the clamping member so that it is driven home and clamps the work-piece with sufficient force to hold it firmly whilst the operator does work to the work-piece.
Summary of the invention
The present invention aims to ameliorate problems associated with known work benches, or improve upon known work bench systems.
In the first aspect, the present invention provides a work bench having at least one clamping cradle into which a work-piece can be received and clamped, said clamping cradle comprising: a first arm having a first surface; an opposing second arm arranged in a non-parallel orientation with respect to the first arm; and a clamping member having a second surface which is substantially parallel to, and faces the first surface, said clamping member being movably disposed on the second arm; said clamping member being moveable by an operator along the second arm so that a clamping force can be applied to a work-piece disposed between the first and second surfaces.
In a second aspect, the present invention provides a work bench comprising a work surface disposed on a support frame, and a clamping device for clamping a work- piece, said clamping device comprising a base portion having a top surface, a manually operable clamping member, and a cradle disposed on said top surface and extending substantially from the base portion, the cradle comprising a first portion and a second portion angled with respect to the first portion, said clamping member being movable by hand and disposed on the second portion and movable between a first and second position along the second portion, and being arranged such that a gap between the first portion and the clamping member changes as the clamping member is moved, whereby the work-piece can be clamped between the clamping member and the first portion.
Advantageously, the clamping member of the first and second aspects of the present invention is manually operated by the user or operator. This provides the operator with a degree of judgement regarding the clamping force applied to the work-piece; the clamping force on the work-piece is determined by the operator. For instance, the operator may wish to apply a relatively light clamping force to limit the likelihood of damage to the work-piece which might otherwise of occurred if the work-piece were clamped in a prior art device which relies on the weight of the work-piece to apply the clamping force, for instance. By 'manual operation' or 'operated by hand', it is meant that the operator can cause the clamping member to be used or moved by either direct or indirect intervention (where a force is applied by hand, foot or the like directly to the clamping member or via an actuator, such as a screw-thread respectively).
Furthermore, the present invention does not rely on the work-piece to operate the vice or clamping member. As a result, the operator can position the work-piece in the clamp in any desired position, location or orientation and clamp it in place with the desired force. The work-piece does not have to rest on a bottom part of the vice for it to be clamped.
Preferably, the clamping member further comprises a handle extending from the clamping member and passing through a channel in the second arm or second portion. This provides relatively easy access for the operator to operate the clamping member.
Disposing the clamping cradle on a work bench adds to the functionality of the work bench. The first and second arms can be arranged vertically. As a result, the work- piece (such as a door) can be held firmly in the vertical orientation.
Advantageously, the clamping cradle is hingeably disposed on a work surface or support frame of the work bench such that the clamping cradle is movable between a stowed position and an operational position relative to the work bench. This allows the clamping cradle to be stowed when not in use, for instance when the work bench is folded for storage. When the clamping cradle is in the stowed position, it should be flush with at least a part of the support frame, and when the clamping cradle is in the operational position it should be arranged substantially perpendicular to and extending from the support frame such that a work-piece can be disposed in the cradle. Advantageously, this allows the work bench to fold for easy storage. Preferably, the first arm is substantially vertical when the clamping cradle is in the operational position.
Preferably, the clamping cradle further comprises a base portion disposed between the first and second arm, said base portion being arranged to support at least a part of a work-piece disposed in the cradle. The base portion is arranged to bear the weight of the work-piece when it is disposed in the clamping cradle. Thus, work- pieces of different thicknesses can be clamped in the same. position within the clamping cradle. The base portion can be arranged, when in use, to be in contact with the surface on which the work bench rests.
Advantageously, the second arm can be hingedly disposed on the work surface or support frame. Advantageously, only the first arm protrudes from the work-piece on
the opposite side of the work bench. Thus, the operator can manoeuvre around the work-piece easily since the second arm and clamping member arranged between the work-piece and work bench, when in use. This has the advantage that the majority of the weight of the work-piece is borne by the cradle or workbench.
A third aspect of the present invention provides a work bench comprising a work surface, said work surface comprising an upper and a lower clamping member, the upper clamping member having a clamping surface arranged opposite to a top surface of the lower clamping member, and the upper clamping member being arranged to be movable between a closed and open position with respect to the lower clamping member such that a work-piece is receivable between the upper and lower clamping member when the upper clamping member is in the open position, the upper clamping member being in communication with, or driven by a stirrup or foot plate such that manual operation of the stirrup or foot plate causes the upper clamping member to move between the open and close to position, and a clamping force can be applied for holding the work-piece between the upper and lower members, wherein when the upper clamping member is in the closed position it forms at least a part of the work surface.
Advantageously, the upper clamping member forms a part of the work surface when it is not being used to clamped a work-piece between the upper and lower clamping members. Thus, other tools or devices can be mounted on the upper clamping member when it is not being used, as described above.
The arrangement of the third aspect of the present invention means that a substantially vertical clamping force is applied to the work-piece. As a result,
relatively large work-pieces can be clamped in the device with ease. Having the upper clamping member flush to the work surface when in the closed position means that the workbench can be used in a conventional manner when the clamping members are not in use.
The upper clamping member can be arranged to be in communication with the stirrup or foot plate via an assemblage or a panel which passes through an aperture in the lower clamping member. This arrangement has the advantage that the linkage between the upper clamping member and the stirrup or foot plate does not protrude above the work surface.
Advantageously, the work bench's support frame should comprise at least one pair of legs hingedly mounted to the work surface and movable between a folded and operational position relative to the work surface, and the assemblage or panel is arranged to cooperate with the at least one pair of legs when in the folded position for securing the at least one per of legs in the folded position. Thus, the pair of legs mounted to the support frame or work surface via hinges can be locked in a folded or stowed position. This arrangement can also be arranged so that the hingedly mounted legs are locked in a similar fashion in an open or operational position.
Advantageously, the stirrup can be arranged to provide a handle for carrying the work bench.
Advantageously, the upper clamping member is flush with the work surface when in the closed position. Thus, when in the closed position, the upper clamping member forms an integral part of. the work surface. .
Advantageously, the upper clamping member comprises a series of apertures, which can provide a means for mounting or locating tools, or other devices on the upper clamping member.
Preferably, clamping surface and top surface of the upper and lower clamping members have substantially the same surface area. Thus, the pressure applied by each clamping member to a work-piece is substantially the same. Furthermore, the clamping surface area of the upper clamping member can be arranged to be substantially equal to the surface area of the top of the work bench.
The present invention also provides a portable woodworking bench that has a clamp attached to a centreboard that allows easy and effective means of securing timber sections primarily for sawing, but also for performing operations associated with shaping or joining individual pieces. The centreboard can be provided with a recess used in the first instance as a foot rest doubling as a means of steadying the bench, securely clamping the work-piece, and following inversion, as a means for transporting the bench. The bench can have two cradles attached to the legs of one side of the bench that, when folded outwards and used in conjunction with specially designed wedges running in guides, can be used to securely clamp large panels of materials (doors, etc) for the purpose of shaping, planing or other operations. The bench can have a separate and additional top jig attaching to the top work surface which allows easy clamping of smaller board sections, planks of wood, etc either singly or in multiple by means of guided horizontally opposed sliding wedges for the purpose of planing to achieve exactly similar dimensions if necessary, and/or performance of other shaping or sanding operations. The work bench is capable of
being folded and inverted the carriage. The work bench can be made either of wood for a combination of metal and plastic.
Detailed description of embodiments of the present invention
Embodiments of the present invention are now described by way of example only and with reference to the accompanying drawings, in which:
Figure 1 shows a perspective view of a work bench embodying the present invention; Figure 2 shows the work bench of figure 1 in a folded configuration and inverted for carrying;
Figure 3 shows a side view of the work bench of figure 1 in a folded configuration;
Figure 4 shows a view of the work bench show in figure 1 or figure 3 with the clamping cradles in an operational or extended position;
Figure 5 shows the work bench of figure 4 as a perspective view, without a work-piece in the cradle;
Figure 6 shows the work bench of figure 5, with the work-piece in the cradle; and Figure 7 shows a clamping device embodying in the present invention.
Referring to figure 1 , a work bench 10 embodying the present invention is shown. The bench comprises a work surface 12 and a stand or support frame 14 which is used during operation to rest the work bench on the ground or on a suitable surface. The support frame comprises four legs for stability during use. At least one pair of legs is attached to the device by hinges to allow the work bench to be folded into a
substantially flat configuration when not in use. This reduces the overall volume occupied by the work bench to ease storage.
The work surface 12 comprises a pair of jaws, in this example upper and lower clamping members 16 and 18 respectively. The top jaw 16 is attached to and driven by a foot stirrup or foot plate via centre board or panel 20 which passes through an aperture in the bottom jaw. The stirrup allows the operator to apply a manual force on the top jaw by placing a foot in the stirrup and either lifting or the stirrup or pressing down on the stirrup. A clamping force can be applied to a work-piece displaced between the jaws by pressing down on the stirrup.
It is relatively easy to place a piece of lumber 22 between the jaws using the following action. The operator can hold the lumber with both hands, and, with their foot in the stirrup, lift the top jaw by a sufficient amount by lifting the stirrup. The lumber can be placed between the jaws and a downward force can be applied by the operator's foot in the stirrup which causes the lumber to be clamped in the jaws. With their foot still applying the downward force, the operator can begin work on the lumber, such as sawing or chiselling, for instance. Because the upper jaw is of a similar size to the lower jaw, the downward force is applied over a large surface area with an even distribution. The large surface area reduces the likelihood of the work- piece being bruised or damaged by the jaws if excessive force is applied by the operator. Having a foot placed on the stirrup provides a comfortable position for the operator to work on the lumber, and it is not necessary to steady the work bench with a free hand if the operator is using a saw.
When not in use, the upper jaw lies flush with the top of the bench. Advantageously, this allows the top jaw to effectively become at least an integral part of the work bench's work surface, when not in use. A series of holes 24 are provided to allow other items, such as surface clamps or the like, to be located in the top surface when the jaw is not being used to clamp a work-piece.
The pair of legs attached to the work bench by hinges is movable between a stowed position and an extended position. In the extended position, the footprint of the work bench is increased to provide additional stability. When these legs are in the stowed position, it is possible to pass the centreboard 20 through a latch (not shown). In this way, the pair of legs can be held securely in the stowed position. This allows the operator to invert, or turn upside down, the work bench and carry the work bench using the stirrup as a handle, as shown in figure 2.
Referring to figure 4, a lower guide 15 can be provided. The guide contains two slots or apertures (not shown) which run longitudinally with respect to the work bench. The slots are arranged to accommodate the centreboard, or panel 20. One slot is arranged to accommodate the panel when the legs of the bench are folded or in the stowed position, and the other slot is arranged to accommodate the panel when the bench's legs are in the open or extended position, for use of the work bench, as shown in figure 4. The leg assembly can be hinged about a point 17, for instance.
Referring now to figures 3 and 4, another feature or embodiment of the present invention is shown. In these figures, features common with those shown in figures 1 and 2 are indicated by the same numerals. Figure 3 shows a side view of the work bench 10. The work bench further comprises a pair of cradles 40. Each cradle is
attached to a leg by a pair of hinges 42. This allows the cradle to be moved from a stowed position (as shown in figure 3) to an operational position where the cradles extend away from the leg to which they are attached (as shown in figure 4).
Each cradle comprises a generally U-shaped section or frame in this example. The frame comprises a first arm 50 which extends substantially vertically from the surface on which the work bench is placed. A base portion 52 is provided between the first arm and a second arm 54. The second arm is angled in a non-parallel orientation with respect to the first arm.
Clamping members or elements 56, which in this example are generally wedged shaped, are provided to clamp a work-piece in the cradle. These clamping elements or large wedges have the effect of securely fixing or holding the work-piece throughout its length, rather than at just one end. In conjunction with the base portion 52 of the cradles, this avoids the need to use scrap pieces of timber beneath the door or work-piece to keep it clear of the floor. This arrangement thus avoids damaging and edge of the work-piece.
In the embodiment shown in Figures 3 and 4, the clamping members are each attached to a handle 58 for moving or sliding the clamping member along the second arm 54. The handles extend through a slot in the portion of the cradle against which they abut. Thus, in this example the handles protrude from an opposite surface of the arm on which the clamping member engages.
As shown in figure 4, when the clamping members are located at the base of the cradle there is no, or little, gap between the. clamping member and the opposite
surface of the first arm 50. It will be appreciated, and described below, that when the clamping members are moved towards the top of the second arm, a relatively large gap will be apparent between the clamping member 56 and the opposing surface of the first arm 50. It is into this gap that the work-piece is received for clamping.
A notch 60 is provided towards the end of the second arm distal from the base portion 52 to provide a means for locating the clamping member in the position which maximises the distance or gap between the clamping member and the first arm. Thus, the clamping members can be located in a position which allows the operator to locate a work-piece between the clamping member and the first arm without having to hold the clamping member towards the top end of the arm.
Figures 5 and 6 show the work bench with the cradles in the extended position, with and without a work-piece 65 in the cradles, respectively. Referring to figure 5, the clamping elements are held in position by the notch cooperating with a corner of the clamping element. As described above, this has the advantage of allowing the operator to place the work-piece in the cradle without having to hold the clamping element in this upper position (without the notch, the clamping member would slide back down the second arm 54 towards the base portion 52 of the cradle 40).
With the work-piece positioned in the cradle 40 and resting with an edge on the base portion 52 of each cradle, the operator can use the handle 58 of each clamping element to move the clamping elements towards the base portion 52. At a point along the second arm 54 the clamping member engages with the work-piece. Further movement of the clamping member towards the base portion causes the clamping member to apply a force on the work-piece so that the work-piece becomes
clamped between the clamping member and the first arm of the cradle. The force can be manually applied by hand, or any other body-part, such as a foot for instance. The magnitude of the force is dependent on how hard the operator pushes the handles down (a hammer blow can be used the apply a greater force than might otherwise have been manually applied). An equal and opposite force is applied to the clamping member and the second arm. Friction between the clamping member and the second arm, and between the clamping member and the work-piece, cause the clamping member to become wedged between the second arm and the work- piece. Likewise, friction between the clamping member and the work-piece, and between the work-piece and the first arm cause the work-piece to become wedged in the cradle. Figure 6 shows the work-piece clamped, or held in position, as described above.
In an alternative arrangement the second arm is hingedly attached to the support frame. This arrangement has the advantage that the first arm protrudes from the vertical face of the work-piece opposite to the work-piece clamped in the cradle, thereby improving access to the work-piece by the user, or operator. In the embodiment shown in the figures, and described above, the second arm and clamping members extend out from the work-piece and can interfere with a user's access to the work-piece. In other words, the alternative arrangement makes it easier for the user to walk around the work-piece clamped in the cradle.
Referring now to figure 7, a further clamping device 75 is shown. The device comprises a base 76 on which a peripheral frame 78 is disposed and supported. The frame stands proud of the base by roughly 1 inch, or 25 millimetres. The frame should not extend around the entire periphery of the base; preferably the frame is
open along one edge of the base. This allows the clamping device to accommodate relatively large or long work-pieces 80. In an alternative arrangement the frame is also open at the opposite end so that relatively long work-pieces can be clamped by the device whilst opposite ends of the work-pieces protruding from either end of the support frame.
To clamp the work-piece in the device, two clamping members 82 are provided. The clamping members operate in a similar fashion to those described above for the cradle clamping device shown in figures 5 and 6. Handles 84 are provided for each clamping member. The handle extends through a channel provided between an angled section 86 of the peripheral frame 78. The handles allow an operator to move the clamping members along the angled edges. The size of a gap between the clamping member 82 and an opposite side 88 of the peripheral frame depends on where the clamping member is disposed in relation to an end of the base. In the example shown in figure 7, the gap between the clamping member 82 and the opposite edge of the frame 88 shortens as the right-hand clamping member is moved to the right-hand edge.
The clamping device can be used to clamp materials of varying thicknesses and lengths, quickly and easily so that operations such as planing, cutting and shaping using hand or power tools can take place. The clamp assembly, or device 76 can be fixed onto the top surface of the main clamping board, or work surface 12 of the work bench 10. This can be done using dowels socketed into pre-drilled holes on the work bench. The clamping member is easily and solidly secure on one or more work- pieces without having to use other clamps, such as screw clamps, and when pressure from the tool, such as a plane, is applied to the top surface of the work-
piece, there is no gap through which the work-piece can slide, as might be the case with known work benches.
The clamping device 75 described above is particularly useful for planing two or more pieces of lumber having the same dimensions. Each clamping member can be used to securely hold one or more work-piece in the device. A plane or sander can then be used on both work-pieces at once, or with one action, to ensure the finished products have substantially the same dimensions.
The drilled holes 24 in the work surface 12 can be used to receive and secure the clamping device 75 and other items of equipment, such as a mitre saw, chop saw or other power tools. They can also be used to accommodate surface clamps which are known in the art.
The work bench can be made from or manufactured using, wood, metal and/or plastic materials.
The skilled person will appreciate that different arrangements of the work bench described above can be provided. For instance, the clamping member handles provide the operator with a means for applying a manual clamping force directly to the work-piece. However, it can be envisaged that a screw-thread type arrangement could be used to indirectly apply a clamping force to the work-piece. Furthermore, an opposing wedge arrangement could be used as an alternative to the clamping elements described above. Also, the handle of the clamping member can be arranged so that the second arm passes through an aperture or channel in the handle.