TITLE: METAL-CUTTING CHOP SAW ACCESSORY

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of provisional application Serial No. 63/298,042 filed 2022, Jan 10 by the present inventor.

FEDERALLY SPONSORED RESEARCH Not Applicable

SEQUENCE LISTING OR PROGRAM Not Applicable

BACKGROUND OF THE INVENTION— FIELD OF INVENTION

This invention relates to metal cutting power tools, specifically to materials alignment and orientation.

BACKGROUND OF THE INVENTION— PRIOR ART

In regard to cutting metallic materials with an abrasive-style chop saw, it is known that some material profiles cut quickly and efficiently, while others do not. The determinant factor between a fast, efficient cut and a laborious, inefficient cut is specifically linked to the contact point between the saw’s abrasive cutting wheel and the material to be cut, and more particularly, to the surface area of that contact point. The smaller the point or points of contact between the wheel and the material, the more effective the cut. Prior to two previous inventions of my own: U.S. Patent 11,072,031 to Ballew (2021) and International Application PCT/ US2021/019486 to Ballew (2021), an abrasive saw’s cutting efficiency had been limited by the geometric relationship between the wheel and the material with no provision for optimizing that geometric relationship.

Although my contributions to the art offer a substantially enhanced cutting efficiency by providing different means for optimizing the geometric relationship between a cutting wheel and a material, significantly different price-point choices for the consumer have been limited. OBJECTS AND ADVANTAGES

Accordingly, several objects and advantages of the present invention are

(a) to provide a tool onto which a material is capable of being oriented so that an improved geometric relationship between the material and a chop saw’s cutting wheel is obtained;

(b) to provide a tool having an attachment means for attaching the tool to a chop saw so that the tool is capable of becoming immovable in relation to the chop saw during cutting operations;

(c) to provide a tool having an alignment means for providing accurate alignment of both the tool and the materials placed onto the tool in relation to the chop saw’s cutting wheel;

(d) to provide a tool that offers fewer components, a lighter weight, and a simpler manufacturing process than those of the prior art; and

(e) to provide a tool whose manufacture requires fewer natural resources than the prior art and thus offers a reduced purchase expenditure for a consumer.

SUMMARY — An accessory tool for a chop saw that provides the optimized cutting geometry of my prior art chop saw cutting deck, but that is securely fitted to existing, prior art chop saws having designs other than my own. The tool is particularly suited for cutting material profiles associated with steel studs, channel iron, and flat stock but can accommodate additional material profiles. In comparison to my prior art cutting deck, the tool’s configuration requires fewer natural resources to produce and provides a reduction in overall weight, thus offering the consumer a choice of features and purchase expenditures.

DRAWINGS— Figures

Fig 1- Chop saw base

Fig 2A- Tool- front perspective

Fig 2B- Tool- rear perspective

Fig 2C- Tool- side view

Fig 3A- Tool deployed on chop saw base

Fig 3B- Tool deployed on chop saw base

Fig 4 A- Alternative clamp embodiment

Fig 4B- Alternative clamp embodiment

Fig 5- Alternative style of chop saw fence

Fig 6- Alternative style of rear mounting boss

Fig 7- Alternative combination of slot and fence

Fig 8A- Detail of alternative mounting boss

Fig 8B- Side view; alternative mounting boss

Fig 9A- Cam-actuated mounting boss

Fig 9B- Cam-actuated boss engaged DRAWINGS — Reference Numerals

20- Chop saw base

21- Cut table

21’ - Longitudinal axis

22- Saw fence

23- Clamp head

24- Clamp screw

25- Clamp screw block

26- Clamp handle

27- Clamp slot

28- Cutting wheel kerf

30- Accessory Tool

31- Cutting deck

31’ - Longitudinal axis

32- Support edge

33 -Drop edge

34- Lower edge

35- Upper edge

36- Front mounting boss

37- Rear mounting boss

38- Tool fence

39- Deck support

40- Toggle clamp

41- Toggle handle

42- Foot screw

42’- Toggle foot

43- Raw material (stud)

44- Accessory Tool- alternative

45- Toggle shuttle

46- Shuttle void

47- Screw

48- Screw bore

49- Shuttle guides

50- Chop saw base

51- Cut table

52- Fence 53- Bore

55- Accessory Tool- alternative

56- Rear mounting boss

60- Chop saw base

61- Cut table

62- Fence

65- Accessory Tool- alternative

66- Cutting deck

67- Rear mounting boss

68- Rear gusset

69- Front gusset

70- Accessory Tool- alternative 70’- Mounting boss- alternative

71- Cutting deck 71’ - Flange

72- Rod bushing

73- Actuator rod

74- Rod pin

75- Cam lever

DETAILED DESCRIPTION— Preferred Embodiment— Figs 1, 2A, 2B, 2C, 3, 4

Fig 1 shows a chop saw base 20 of a typical metal-cutting chop saw. (The chop saw’s motor and cutting wheel are not shown.) Base 20 comprises a horizontally-referenced cut table 21, a fence 22, a clamp head 23, a clamp screw 24, a clamp screw block 25, and a clamp handle 26. Table 21 comprises a planar surface having two side edges substantially parallel to a longitudinal axis 21’. A clamp slot 27 is formed into table 21 and is parallel to axis 21’. Head 23 is mounted into slot 27 so that it is capable of controlled, longitudinal movement. A kerf 28 is also formed into table 21 and is parallel to axis 21’. Kerf 28 is oriented so that a cutting wheel (not shown, but whose longitudinal axis is parallel to its flat, outer surfaces and to axis 21’) is able to pass through the planar surface of table 21 during cutting operations.

Fig 2A shows the preferred embodiment tool 30 of the present invention. An inclined cutting deck 31 is formed of a rigid, planar material of sufficient strength to support raw stock materials to be cut. Deck 31 comprises two side edges 32 and 33. Edges 32 and 33 are parallel to a longitudinal axis 31’ of deck 31. When tool 30 is deployed (as in Fig 3 A) onto a chop saw having a kerf configuration as in Fig 1, edge 32 is furthest from kerf 28 and serves as the support edge. Edge 33 is the edge nearest kerf 28 and is the drop edge. A lower edge 34 at the bottom of the incline and an upper edge 35 at the top of the incline are parallel to one another and are at a right angle to axis 31’. Lower edge 34 contacts table 21 when tool 30 is deployed, and is constructed to preclude interference with clamp components 23, 24, and 25. A front mounting boss 36 serves as a mounting means for mounting tool 30 to table 21. Boss 36 is of a predetermined orientation and configuration that meet all criteria for both sub-categories of mounting means. The two sub-categories of mounting means comprise an alignment means for aligning tool 30 relative to table 21 and a fastening means for securely fastening tool 30 to base 20. (The alignment means criteria for any embodiment of the tool of the present invention, when deployed, is that the orientation and use of the alignment means [1] must align the tool in an orientation relative to the saw so that an intersection between a plane congruent with the planar surface of the tool’s cutting deck and a plane congruent with the planar surface of the saw’s cut table is at a right angle to the cut table’s longitudinal axis; and that its orientation and use [2] must align the tool so that its drop edge is substantially next to but not intersecting a plane [a] that is perpendicular to a chop saw cut table and [b] whose cross section at its intersection with the planar surface of a chop saw cut table is congruent with the cutting wheel kerf. The attachment means criterion for any embodiment of the accessory tool of the present invention, when deployed, is that the orientation and use of the attachment means must immovably affix the tool to a chop saw body throughout all cutting operations.)

Boss 36 of the preferred embodiment is therefore in the form of a tab having predetermined dimensions that fit with a predetermined tolerance into slot 27 so that its location on tool 30 places the tool, when deployed, into an orientation that meets the above alignment means criteria. As noted, boss 36 also serves as an attachment means. The tab of boss 36 is therefore also of a size and orientation capable of being positioned beneath clamp head 23, thereby enabling tool 30 to be secured to table 21 and thus also meeting the above attachment criterion. (The term used in the claims for slot 27 and any feature engaging or communicating with a mounting boss is referred to as a mounting boss receptacle means.) Fig 2A also shows a fence 38 against which raw stock materials rest during cutting operations. Fence 38 comprises two tabs punched from deck 31, as shown, and whose faces are oriented toward edge 35. A plane across the faces of fence 38 is at a right angle to axis 31’, and is perpendicular to deck 31. A materials toggle clamp 40 is joined at a predetermined location to deck 31 by acceptable means of sufficient strength, such as rivets or hardened nuts and bolts (not shown) through deck 31 and into clamp 40, so that raw materials are capable of being sufficiently secured during cutting operations.

Fig 2B shows a deck support 39 joined to deck 31 at upper edge 35 so that deck 31 is supported in an inclined orientation in relation to table 21 (as in Fig 3A). Support 39 comprises parallel top and bottom edges, as shown. A rear mounting boss 37 is joined to deck support 39, as shown, and serves as both an alignment means and an attachment means. For use with the style of saw base illustrated in Fig 1, boss 37 is configured as a tab of a predetermined dimension and is oriented so that it fits with a predetermined tolerance into slot 27 to meet noted alignment criteria, yet is further capable of being inserted beneath fence 22 for securely fastening to table 21, thereby meeting the attachment criterion. Fig 2C shows a side view of support 39 as substantially perpendicular to table 21 when deployed. Alignment bosses 36 and 37 are shown as oriented below the planar surface of table 21. The vertical height of support 39 determines the inclination angle of deck 31. Angle of inclination of deck 31 is predetermined for greatest efficiency for each manufacturer’s model of chop saw.

Fig 3A shows tool 30 deployed onto base 20 with boss 36 properly positioned into the mounting boss receptacle of slot 27. Clamp components 23, 24, 25, and 26 have been removed for clarity. Fig 3B shows tool 30 deployed onto base 20 with rear alignment boss 37 properly positioned into the mounting boss receptacle of slot 27. Fence 22 is removed for clarity.

OPERATION — Preferred Embodiment — Figs 1, 2C, 3 A, 3B

To deploy tool 30, clamp head 23 (Fig 1) is retracted away from fence 22 until fully retracted. Tool 30 is placed onto table 21 so that alignment bosses 36 and 37 engage with slot 27, as in Figs 3A and 3B. Tool 30 is then slid rearward against fence 22 so that rear boss 37 slides under fence 22 until support 39 contacts fence 22. Clamp head 24 is then extended away from block 25 until head 24 is screwed with sufficient torque into position over front boss 36. Tool 30 is now aligned and secured onto base 20. Toggle clamp handle 41 is raised, as in Fig 2C, thereby also raising clamping foot 42’. A raw material (stud 43) is placed onto deck 31 and against fence 38. In Fig 3B, screw 42 has been adjusted for cutting studs and handle 41 has been toggled down to press foot 42’ onto material. Proceed with cut per saw manufacturer recommendations.

Alternative Embodiment with Toggle Shuttle — Detailed Description — Figs 4A, 4B

Fig 4A shows an alternative tool 44. Tool 44 is constructed in identical fashion as tool 30, with the exception of the mounting method of clamp 40 to tool 44. Clamp 40 is joined to a clamp shuttle 45 by sufficient means, such as rivets or nuts and counter-sunk screws (not shown) through shuttle and into clamp 40. A void 46 is formed into a portion of deck 31 and support 39, as shown. Void 46 is of a predetermined dimension to receive shuttle 45 so that clamp 40 is capable of longitudinal movement parallel to axis 31’. After shuttle 45 is assembled into void 46, a socket head screw 47 is threaded into a threaded bore 48 from the side opposite clamp 40 and serves as a shuttle retainer to prevent shuttle 45 from unintentionally separating from tool 44.

Fig 4B shows the underside of tool 44. This view details the shuttle support guides 49 in the form of two opposing angle irons joined to the bottom of deck 31. The dimensions and orientations of guides 49 are such that shuttle 45 is capable of longitudinal movement within predetermined parameters, and so that shuttle 45 is supported with a predetermined clearance between it and the bottom of deck 31. Operation — Alternative Embodiment with Toggle Shuttle — Figs 4A, 4B

To use tool 44 with a chop saw base configuration similar to Fig 1, tool 44 is mounted to table 21 using the same steps as with the preferred embodiment tool 30 detailed above. With tool 44 aligned and attached, clamp handle 41 is raised, as in Fig 2C, and shuttle is moved rearward toward edge 35. Raw material stock, such as a stud 43, is placed onto deck 31 and against fence 38, as in Fig 3B. Shuttle 44 is moved forward toward edge 34 to the desired position, and handle 41 is toggled down to press foot 42’ against material. Screw 42 may be adjusted for varying material thicknesses. Proceed with cut per saw manufacturer recommendations.

First Alternative Mounting Boss — Description — Figs 5, 6

On at least one model of chop saw, a base 50 uses a fence 52 that is mounted directly to table 51 rather than through slot 27. As such, slot 27 terminates at a given distance from fence 52, as shown. This scenario disallows use of a rear mounting boss of the type employed with the preferred embodiment. A feature unique to this model of saw is the presence of one or more bores 53 through its fence. These bores are of a dimension capable of serving as mounting boss receptacles. Fig 6 shows an alternative tool 55 which has two mounting bosses 56 in the form of posts joined to support 39. Bosses 56 are sized and oriented to communicate with bores 53 so that their orientation also meets both the alignment criteria and the attachment criterion for the tool. The features of this saw accommodate the front boss of the preferred embodiment and require no alteration.

First Alternative Mounting Boss — Operation — Figs 5, 6, 2C, 3B

To use tool 55 with a chop saw having a base similar to base 50, head 23 is fully retracted away from fence 52. Tool 55 is placed onto table 51. Tool 55 is moved into a position against fence 52 so that bosses 56 engage bores 53 and until support 39 contacts fence 52. Front boss 36 is positioned into slot 27 and head 23 is extended until it has been sufficiently torqued into position over boss 36. With tool 55 aligned and attached, clamp handle 41 is raised, as in Fig 2C. Raw material is placed onto deck 31 and against fence 38, as in Fig 3B, and handle 41 is toggled down to press foot 42’ against material. Proceed with cut per saw manufacturer recommendations.

Second Alternative Mounting Boss — Description and Operation — Figs 7, 8A, 8B

Fig 7 shows another style of chop saw with a base 60 similar to base 50 with the exception that fence 62 lacks the bores in fence 51. As with base 50, the fence is mounted to table 61 rather than into slot 27, so slot 27 is separated from fence 62, as shown. This scenario requires another alternative mounting boss. Fig 8A shows one such possibility with mounting boss 67. Because boss 67 extends a substantial distance from the underside of deck 66 (Fig 8B), it is stabilized laterally by having greater width where it joins deck 66 and longitudinally by way of gussets 68 and 69 joined to the rear and front of boss 67, as shown. Fig 8B shows the horizontal tab portion of boss 67 as extending through slot 27 to hook under the underside of cut table 61 when deployed. Front boss 36 provides alignment and attachment by its position into slot 27 and its orientation beneath head 23.

Operation of this embodiment is identical to either the preferred embodiment or the first alternative embodiment, depending upon the style of clamp mounting method used.

Third Alternative Mounting Boss — Description — Figs 9A, 9B

The preceding embodiments have utilized the clamping components of a chop saw base to facilitate attachment of the tool to a saw. In scenarios where it is desired to mount the tool to a chop saw whose clamp components are inoperable or non-existent, an alternative mounting boss is needed. Fig 9A shows an alternative mounting boss 70’ that may be used without clamp components. In this embodiment, the lower half of a two-piece rod bushing 72 is inserted up through a bore in a mounting flange 71’ of accessory tool 70. The lower half of bushing 72 comprises a lower alignment portion that fits with a predetermined tolerance into slot 27, and has a height equal to or less than the thickness of the chop saw’s cut table 21 around slot 27. This lower half of bushing 72 also comprises threads at its upper portion capable of mating with threads of the upper half of the bushing. The bore in flange 71’ for bushing 72 is oriented so that when tool 70 is deployed, boss 70’ aligns and attaches the tool to satisfy all noted alignment and attachment criteria.

The upper half of rod bushing 72 is threaded onto the threaded portion of the lower half, as shown. An actuator rod 73 of a predetermined dimension for proper operation comprises a rod bore 74’ in its upper end. Bore 74’ has a central axis that is perpendicular to the rod’s central, longitudinal axis; and has a diameter capable of receiving a rod pin 74. Rod 73 passes through a center bore in bushing 72 and is rigidly joined to a clamp foot 76 so that a plane along the lengthwise edge of foot 76 is perpendicular to the central axis of rod bore 74’. The length of foot 76 is greater than the width of slot 27 by a predetermined amount, and its width of foot 76 is equal to or less than the width of slot 27 so that the foot may pass through the slot when properly oriented.

A cam lever 75 is joined to the top of rod 73. Lever 75 comprises a groove parallel to its longitudinal axis and a cam bore perpendicular to its longitudinal axis. The groove is of a dimension to accept rod 73, as shown, and the cam bore is of a size capable of receiving rod pin 74. The cam bore is oriented in a predetermined location in lever 75 so that when pin 74 is assembled through the cam bore and the rod bore 74’, a downward force applied to cam lever 75 is capable of providing a prescribed amount of upward vertical movement to rod 73 so that tension is applied to the underside of table 21 by foot 76. The resultant tension is of a predetermined amount to immovably fasten the tool to the chop saw cut table throughout all cutting operations. Boss 70’ may be oriented on the tool wherever suitable. Third Alternative Mounting Boss — Operation — Figs 9A, 9B

To deploy tool 70 configured with boss 70’onto a compatible chop saw, cam lever 75 is placed into a raised position and oriented to that its longitudinal axis is parallel to slot 27. Tool 70 is placed onto cut table 21 so that foot 76 passes into and through slot 27 and so that all mounting bosses are engaged with their respective mounting boss receptacles. Cam lever 75 is then rotated 90 degrees and depressed until sufficient upward force is exerted on foot 76 so that tool 70 is joined to table 21 in an immoveable fashion. Follow saw manufacturer recommendations to proceed with cut. Tool removal is the reverse of deployment.

Conclusion, Ramifications and Scope of Invention —

Thus the reader will see that the alignment and orientation accessory of the present invention provides a tool to improve the efficiency of cutting metal with a metal-cutting chop saw and also provides a tool that may be used with existing chop saws without a need to purchase an additional power tool. While my above description contains many specificities, these should not be construed as limitations on the scope of the invention, but as an exemplification of the preferred embodiments thereof. Many other variations are possible, as discussed below.

Depending upon the geometry of the individual chop saw model, the incline of deck 31 may also be reversed so that the downward slope is toward the rear of the saw. Such an orientation would optimally place the accessory fence toward the rear, thus allowing the intended use of the chop saw’s fence. Such an orientation also allows placement of a clamp block and clamp head onto the tool’s cutting deck at the elevated front of the saw. Similarly, the inclined deck of the tool may also be constructed to be reversible, meaning that the tool may employ components that allow the tool to be properly oriented with the incline towards the front or towards the rear of the chop saw at the operator’s discretion.

A toggle clamp is primarily used to secure materials to the tool’s cutting deck and into proper orientation to the saw’s cutting wheel. For more permanent use of the tool, a possible embodiment is to configure the tool to accept the saw’s existing clamp components by which to clamp materials against the tool’s fence. A materials clamp may alternately mount directly to the fence.

Mounting boss 70’ is shown as having a clamp foot 76 that projects into and through slot 27, while other embodiments show tabs or studs that communicate with existing saw features. Mounting boss shape, size, quantity, and location is specific to the brand and model of chop saw in order to provide precise alignment and safe, secure attachment of the tool. As such, mounting bosses such as clamping foot 76 may be sized to accommodate any number of mounting boss receptacles. Likewise, any mounting boss, including boss 70’, may be positioned in a vertical, horizontal, inverted, or any other position to facilitate engagement with a given mounting boss receptacle. The tool of the present invention shows a fence punched from the deck material into a specific orientation. To facilitate manufacturing, it may be desirable to weld or otherwise join a fence to the cutting deck, or to bend a specifically shaped and oriented portion of deck material into the form of a fence. A prefabricated fence may also be added to the tool. Alternately, the tool may employ the saw’s fence or its materials clamp for the intended purpose and in accordance with the tool’s objects and advantages.

The specification has thus far presented a tool having mounting means that consolidate various alignment means with different attachment means into a single element that performs both mounting functions simultaneously. Due to the unforeseen configuration of future or presently unknown chop saw bodies, the alignment means and the attachment means may consist of two distinct elements. In such a scenario, an alignment means might laterally align the tool with the saw, but not securely attach the tool to the saw. In like manner, a given attachment means might safely hold the tool at a consistent elevation in relation to a saw’s cut table, but lacks the means to secure it into a specific lateral orientation.

Accordingly, the scope of the invention should be determined not by the embodiments illustrated, but by the appended claims and their legal equivalents.