Powered cutting saw system
First Claim
1. A cutting saw, comprising:
- a motor that induces rotary motion in a shaft;
a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft;
an elongated saw-bar mounted to the plate, the saw-bar having a perimeter;
a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material;
a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; and
a depth stop that limits movement of the plate relative to the base to a plurality of third positions that are between the first and second positions;
wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position.
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Accused Products
Abstract
A plate-joinery system includes a chain-saw plate joiner where the cutting mechanism includes a cutting-chain driven about a saw-bar. The cutting mechanism of the chain-saw plate joiner may be advanced on rails to one of a set of predetermined depths. The increased recess depth allowed by the chain-saw and the resultant increase in both glueable surface area and mechanical engagement permit high-strength right-angle joints to be made with the speed of conventional plate-joinery. Plate-joints of more conventional proportion may also be made. The plate joinery system also includes specialty plate configurations and compatible fasteners that permit many joints to be rapidly assembled without resort to either manual glue application or external clamps. A series of high-precision, low-friction cutting devices suitable for general introduction is also described.
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Citations
43 Claims
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1. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; and a depth stop that limits movement of the plate relative to the base to a plurality of third positions that are between the first and second positions; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position.
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2. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; and a depth stop that limits movement of the plate relative to the base to at least one third position that is between the first and second positions; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position; and wherein the depth stop includes means for finely adjusting the at least one third position.
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3. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; and a depth stop that limits movement of the plate relative to the base to at least one third position that is between the first and second positions; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position; and wherein the depth stop includes a sliding bolt.
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4. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; and a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position; and wherein the plate includes at least one mounting feature that permits the plate to be mounted on a stationary stand. - View Dependent Claims (5)
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6. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; and a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position; wherein the base has a forward edge and a rearward edge, the saw-bar and the cutting-chain being enclosed within the forward and rearward edges of the base when the plate is in the first position and only the portion of the saw-bar and the cutting-chain being enclosed within the forward and rearward edges of the base when the plate is in the second position, and wherein the forward edge of the base include an opening that permits the remaining portion of the saw-bar and the cutting-chain to protrude therethrough when the plate is in the second position; and wherein a rearward portion of the base that is proximate to the rearward edge includes a plurality of curved vanes that deflect the solid material removed by the at least one tooth in a predetermined direction. - View Dependent Claims (7)
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8. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; and a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position; wherein the base has a forward edge and a rearward edge, the saw-bar and the cutting-chain being enclosed within the forward and rearward edges of the base when the plate is in the first position and only the portion of the saw-bar and the cutting-chain being enclosed within the forward and rearward edges of the base when the plate is in the second position, and wherein the forward edge of the base include an opening that permits the remaining portion of the saw-bar and the cutting-chain to protrude therethrough when the plate is in the second position; and wherein the forward edge of the base includes a substantially planar reference face that is perpendicular to the saw-bar. - View Dependent Claims (9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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20. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; and a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position; wherein the base has a forward edge and a rearward edge, the saw-bar and the cutting-chain being enclosed within the forward and rearward edges of the base when the plate is in the first position and only the portion of the saw-bar and the cutting-chain being enclosed within the forward and rearward edges of the base when the plate is in the second position, and wherein the forward edge of the base include an opening that permits the remaining portion of the saw-bar and the cutting-chain to protrude therethrough when the plate is in the second position; and wherein the base includes at least one gate that is slidably disposed in the opening in the forward edge of the base, the gate being movable between a third position and a fourth position, the third position minimizing a size of the opening in the forward edge of the base and the fourth position maximizing the size of the opening in the forward edge of the base. - View Dependent Claims (21, 22, 23)
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24. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; and a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position; and wherein an extended portion of the saw-bar and the cutting-chain that is not enclosed by the base when the plate is in the second position includes three geometrically distinct perimeter arcs, the three distinct perimeter arcs including a nose-arc and two side-arcs, the two side-arcs being equal to one another, opposite in orientation, positive in curvature, and substantially continuous with and substantially tangent to the nose-arc at points of connection between the three distinct perimeter arcs. - View Dependent Claims (25)
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26. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; and a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position; wherein the motor includes a switch having a first state that permits the motor to induce rotary motion in the shaft and a second state that prevents the motor from inducing rotary motion in the shaft; wherein the base includes an upper base and a lower base that are mechanically coupled together to form the base; and wherein separation of the upper base from the lower base sets the switch to the second state.
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27. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; and a plurality of freely-turning bearings interposed between the cutting chain and the saw-bar, so that when tension is introduced between the cutting chain and the saw-bar, a majority of the tension is borne by the bearings; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position. - View Dependent Claims (28, 29, 30)
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31. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; and a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position; and wherein the cutting-chain includes a plurality of links including a first link and a second link, the first link having a leading edge and the second link having a trailing edge, and wherein the leading edge of the first link and the trailing edge of the second link have complementary mating surfaces, the complementary mating surfaces inducing articulation between the first link and the second link as the cutting-chain rotates about the perimeter of the saw-bar.
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32. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; and a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position; and wherein the complementary mating surfaces of the leading edge of the first link and the trailing edge of the second link include at least one recess and at least one protrusion.
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33. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; and a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position; wherein the base encloses the saw-bar and the cutting-chain in the first position, and wherein the base encloses only a portion of the saw-bar and the cutting-chain in the second position; and wherein the cutting-chain includes a plurality of successive links, each respective link of the plurality of successive links including a first stop that prevents articulation between the respective link and the immediately preceding link greater than a predetermined radius. - View Dependent Claims (34)
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35. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; an elongated saw-bar mounted to the plate, the saw-bar having a perimeter; a cutting-chain entrained about the perimeter of the saw-bar and about the shaft so that rotation of the shaft induces rotary motion of the cutting-chain about the perimeter of the saw-bar, the cutting-chain including at least one tooth that is capable of removing solid material; and a plurality of freely-turning bearings interposed between the cutting chain and the saw-bar, so that when tension is introduced between the cutting chain and the saw-bar, a majority of the tension is borne by the bearings. - View Dependent Claims (36, 37, 38, 39)
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40. A cutting saw, comprising:
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a motor that induces rotary motion in a shaft; a plate that is mounted to the shaft so that the shaft can be held stationary relative to the plate on all axes except a longitudinal axis of the shaft, whereby the shaft can be freely rotated about the longitudinal axis of the shaft; at least one cutting-tooth mounted about the shaft so that rotation of the shaft rotates the at least one cutting-tooth about the shaft; a base that is slidably mounted to the plate to permit the plate to move relative to the base between a first position and a second position, the base having a forward edge with an opening through which the at least one cutting-tooth can protrude, the at least one cutting-tooth being enclosed by the base within the forward edge in the first position and extending beyond the forward outside the base through the opening in the second position; and at least one gate slidably disposed in the opening in the forward edge of the base, the gate being movable between a third position and a fourth position, the third position minimizing a size of the opening in the forward edge of the base and the fourth position maximizing the size of the opening in the forward edge of the base. - View Dependent Claims (41, 42, 43)
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Specification