Table saw including an attached table extension

Abstract

A table saw includes a table work surface, main rails supported on opposite sides of the table work surface, and a fence mounted on the main rails so as to be slidable relative to the table work surface. The table saw also includes an extension assembly having extension rails supporting an extension work surface and a connector assembly coupling the extension rails to the main rails. The main rails and the extension rails together provide a continuous fence contact surface that extends along the entire length of the table top and the extension assembly. The connector assemblies each include a hook that engages with a latch plate and the hook is assembled with the latch plate via a pivoting action.

Description

Background Technology

[0001] Table saws of various designs include a frame and an upward-facing working surface with an opening through which the blade extends. The working surface supports materials such as wood when pushed against the blade for cutting. Traditionally, table saws have been a stand-alone piece of equipment used in workshops. Because most stand-alone table saws are used in large open spaces, the size of the table saw (including the working surface) can be large enough to support materials of various sizes for cutting. However, due to the size and weight of such table saws, they are not easily moved from one location to another. On construction sites, it is useful to have table saws that can be easily moved from one location to another or between different construction sites. Therefore, smaller and more portable table saws have been designed. Portable table saws use lighter materials and reduce the size of the frame and working surface to reduce the size and weight of the table saw, thereby allowing for portability.

[0002] A table saw may include a movable fence supported on a track positioned on the opposite side of the work surface. The fence provides a guide surface against which the material to be cut is positioned. During cutting operations, as the material is cut by the saw blades, it rests on the work surface while sliding along the fence. Because the fence is arranged perpendicular to the work surface and generally parallel to the blades, it allows the table saw to provide accurate, straight, and reproducible cuts. The fence can be positioned relative to the work surface by sliding it along the track to a desired distance from the blades and securing it in the desired position using a locking mechanism.

[0003] The kerf size in the material is determined by the distance between the guardrail and the blade, and therefore the maximum cutting size (e.g., sawing capacity) of the table saw is limited by the distance between the guardrail and the blade, which can be positioned, and this distance is in turn limited by the length of the track. Due to their relatively small size, portable table saws can have relatively short tracks and are therefore often associated with relatively small sawing capacities. It is desirable to provide a portable table saw that offers a relatively large sawing capacity. Summary of the Invention

[0004] In some aspects, a connector assembly is configured to connect one end of a first track to one end of a second track. The connector assembly includes: a latch plate disposed on an end face of one of the first and second tracks; and a hook projecting from the end face of the other of the first and second tracks. The hook includes a curved protrusion. This protrusion engages a track-facing surface of the latch plate such that the hook is held on the latch plate, and the longitudinal axis of the second track is parallel to the longitudinal axis of the first track.

[0005] In some embodiments, the latch plate includes a latch plate opening, and the hook includes a mounting plate that is secured to the end face of the other of the first and second tracks. Additionally, a protrusion projects from the mounting plate, extends through the latch plate opening, and engages the track-facing surface of the latch plate.

[0006] In some embodiments, the protrusion is configured such that when the protrusion engages with the latch plate, a portion of the mounting plate abuts a portion of the latch plate and a portion of the protrusion abuts a portion of the latch plate opening.

[0007] In some embodiments, the portion of the mounting plate, the portion of the latch plate, the portion of the protrusion, and the portion of the latch plate opening each include a two-dimensional surface.

[0008] In some embodiments, the latch plate includes a hook-facing surface and a first track-facing surface opposite to the hook-facing surface. The first track-facing surface abuts an end face of one of the first and second tracks. The latch plate includes a latch plate peripheral edge extending between the hook-facing surface and the first track-facing surface. Additionally, the latch plate includes a latch plate opening extending between the hook-facing surface and the first track-facing surface and surrounded by the latch plate peripheral edge. The mounting plate includes a latch plate-facing surface and a second track-facing surface opposite to the latch plate-facing surface. The second track-facing surface abuts an end face of the other of the first and second tracks. Additionally, the mounting plate includes a mounting plate peripheral edge surrounding a protrusion and extending between the latch plate-facing surface and the second track-facing surface.

[0009] In some embodiments, the protrusion is configured such that when the protrusion engages with the latch plate, a portion of the latch plate-facing surface of the mounting plate abuts a portion of the latch plate-facing hook-shaped surface, a portion of the protrusion-facing mounting plate abuts a portion of the first track-facing surface of the latch plate, and a portion of the protrusion abuts a portion of the latch plate opening.

[0010] In some embodiments, the surface of the mounting plate facing the latch plate includes an angled portion, thereby creating a gap between the latch plate and a portion of the mounting plate.

[0011] In some embodiments, the hook includes a mounting plate and a catch, wherein the catch includes a protrusion.

[0012] In some aspects, a track assembly includes a first track connected to a second track via a connector assembly. The first track includes a first end, a second end opposite to the first end, and a first longitudinal axis extending between the first and second ends. The second track includes a first end, a second end opposite to the first end, and a first longitudinal axis extending between the first and second ends. The connector assembly includes a latch plate disposed on an end face of one of the first and second tracks; and a hook projecting from the end face of the other of the first and second tracks. The hook includes a curved protrusion. The protrusion engages a track-facing surface of the latch plate such that the hook is held on the latch plate, and the longitudinal axis of the second track is parallel to the longitudinal axis of the first track.

[0013] In some embodiments, the latch plate includes a latch plate opening, the hook includes a mounting plate fixed to the end face of the other of the first and second tracks, and a protrusion protrudes from the mounting plate, extends through the latch plate opening, and engages the track-facing surface of the latch plate.

[0014] In some aspects, a table saw includes a table working surface. The table working surface includes an opening configured to receive a cutting blade, and first, second, third, and fourth sides surrounding the table working surface. The table saw includes: a main rail supported on the first side; and an extension assembly including an extension rail and a connector assembly configured to connect the extension rail to the main rail. The table saw includes a guardrail supported on one of the main rail and the extension assembly to allow sliding relative to the table surface. The connector assembly includes: a latch plate disposed on an end face of one of the main rail and the extension rail; and a hook projecting from an end face of the other of the main rail and the extension rail. The hook includes a curved protrusion. The protrusion engages a rail-facing surface of the latch plate such that the hook is held on the latch plate, and the longitudinal axis of the extension rail is parallel to the plane defined by the table working surface.

[0015] In some embodiments, the longitudinal axis of the extended track is parallel to the longitudinal axis of the main track.

[0016] In some embodiments, the latch plate includes a latch plate opening, the hook includes a mounting plate fixed to the end face of the other of the main rail and the extension rail, and the protrusion protrudes from the mounting plate, extends through the latch plate opening, and engages the rail-facing surface of the latch plate.

[0017] In some embodiments, the protrusion is configured such that when the protrusion engages with the latch plate, a portion of the mounting plate abuts a portion of the latch plate and a portion of the protrusion abuts a portion of the latch plate opening.

[0018] In some embodiments, the portion of the mounting plate, the portion of the latch plate, the portion of the protrusion, and the portion of the latch plate opening each include a two-dimensional surface.

[0019] In some embodiments, the latch plate includes a hook-facing surface and a first track-facing surface, the first track-facing surface opposing the hook-facing surface and abutting an end face of one of the main track and the extension track. The latch plate includes: a latch plate peripheral edge extending between the hook-facing surface and the first track-facing surface; and a latch plate opening. The latch plate opening extends between the hook-facing surface and the first track-facing surface and is surrounded by the latch plate peripheral edge. The mounting plate includes a latch plate-facing surface and a second track-facing surface, the second track-facing surface opposing the latch plate-facing surface and abutting an end face of the other of the main track and the extension track. Additionally, the mounting plate includes a mounting plate peripheral edge surrounding a protrusion and extending between the latch plate-facing surface and the second track-facing surface.

[0020] In some embodiments, the protrusion is configured such that when the protrusion engages with the latch plate, a portion of the latch plate-facing surface of the mounting plate abuts a portion of the latch plate-facing hook-shaped surface, a portion of the protrusion-facing mounting plate abuts a portion of the first track-facing surface of the latch plate, and a portion of the protrusion abuts a portion of the latch plate opening.

[0021] In some embodiments, the table saw includes an extended working surface supported on an extended track so as to be coplanar with the table working surface.

[0022] In some embodiments, the work surface is supported relative to the support surface via a support structure, and the extension assembly includes a support leg connected to the extension work surface and can be configured to extend between the extension track and the support surface.

[0023] In some embodiments, the extension track extends from the main track via a connector assembly.

[0024] In some embodiments, the main rail is a first main rail, and the table saw includes a second main rail supported on a third side of the table surface. The extension rail is a first extension rail, and the extension assembly includes a second extension rail. The connector assembly is a first connector assembly that connects the first extension rail to the first main rail, and the extension assembly includes a second connector assembly that connects the second extension rail to the second main rail. The second connector assembly includes a latch plate disposed on an end face of one of the second main rail and the second extension rail. Additionally, the second connector assembly includes a hook that protrudes from the end face of the other of the second main rail and the second extension rail. The hook includes a curved protrusion. This protrusion engages a rail-facing surface of the latch plate such that the hook is held on the latch plate, and the longitudinal axis of the second main rail is parallel to the longitudinal axis of the second extension rail.

[0025] In some embodiments, the table saw includes an extended working surface supported on a first extension rail and a second extension rail so as to be coplanar with the table working surface.

[0026] In some embodiments, the main track and the extension track each include a profiled surface configured to engage with the track contact surface of the rail panel. The peripheral edge of each of the latch plate and the mounting plate includes a profiled portion having the same profile as the profiled surfaces of the main track and the extension track, and the profiled portions of the peripheral edges of the latch plate and the mounting plate cooperate with the profiled surfaces of the main track and the extension track to provide a continuous rail panel contact surface configured to allow the rail panel to slide along both the main track and the extension track.

[0027] In some aspects, a table saw assembly includes a table saw and an extension table. The table saw includes a working surface comprising an opening configured to receive a cutting blade, a first main rail supported on one side of the working surface, and a second main rail supported on a second side of the working surface. The second side is on the working surface opposite to the first side. The table saw assembly includes a guardrail mounted on the first and second main rails to allow sliding relative to the working surface. The extension table includes: a first extension rail; a second extension rail extending parallel to the first extension rail; and an extension working surface extending between and supported on the first and second extension rails such that the extension working surface is coplanar with the working surface. The extension table includes a first connector assembly configured to connect the first extension rail to the first main rail. The extension table includes a second connector assembly configured to connect the second extension rail to the second main rail. The first connector assembly and the second connector assembly each include: a latch plate disposed on an end face of one of the main track and the extension track; and a hook protruding from the end face of the other of the main track and the extension track. The hook includes a curved protrusion. The protrusion engages the track-facing surface of the latch plate such that the hook is held on the latch plate, and the longitudinal axis of the extension track is parallel to the plane defined by the table working surface.

[0028] In some embodiments, the extension table extends from the table saw via a first connector assembly and a second connector assembly.

[0029] In some embodiments, the extension table is connected to the table saw via a first connector assembly and a second connector assembly. The table working surface is supported relative to a support surface via a support structure, and the extension table includes a support leg connected to the extension working surface and can be configured to extend between the extension working surface and the support surface.

[0030] In some embodiments, the extension table is a cantilevered extension table extending from the table saw via a first connector assembly and a second connector assembly. The table saw assembly includes a supported extension table comprising a third extension rail and a fourth extension rail extending parallel to the third extension rail. The supported extension table includes a supported extension working surface extending between and supported on the third and fourth extension rails such that the supported extension working surface is coplanar with the table working surface. The supported extension table includes a support leg connected to the supported extension working surface and configured to extend between the supported extension working surface and the support surface. The supported extension table includes: a third connector assembly configured to connect the third extension rail to one of a first main rail and a first extension rail; and a fourth connector assembly configured to connect the fourth extension rail to one of a second main rail and a second extension rail.

[0031] In some aspects, a portable table saw includes: a table having a table working surface; and a pair of main rails (e.g., a front main rail and a rear main rail) supported on opposite sides of the table working surface. The main rails allow operation of the guardrail in a small, compact size and for small rip capabilities. Additionally, the portable table saw includes an extension assembly that increases the operability of the ripped guardrail and thus increases the sawing capacity. The extension assembly includes a pair of extension rails and an extended working surface supported on the extension rails. The extension rails can be connected to the main rails or to an extension rail of another extension assembly. The extension rails have guide surfaces for the guardrail that mate with guide surfaces of the main rails. When the extension rails are connected to the main rails, the corresponding guide surfaces of the main rails and extension rails are continuous, and the portable table saw provides a fully functional, fixed extension rail on which the guardrail can be operated for substantially the entire length of the extension rail. The extension rails also allow the use of a fixed measuring scale. The extension rails support the extended working surface such that it is adjacent to and coplanar with the table working surface. When larger cutting sizes are not required or during transport of a portable table saw, the extension rail can be easily detached from the main rail for storage. The extension rail can be attached to and detached from the main rail without the use of tools or fasteners.

[0032] In some embodiments, the pair of extension rails may be tethered to the table saw, while in other embodiments, multiple pairs of extension rails may be untethered and therefore completely detachable, allowing for a lighter table saw. Detachable, untethered extension rails can benefit users who do not require high cutting power and those who prefer to carry multiple lightweight bundles.

[0033] In some embodiments, the extension rail is cantilevered to the table saw. In other embodiments, the extension rail may house or include separate support legs. Using an extension rail with support legs can be advantageous for very long rails. For example, by providing support legs when using very long extension rails, the situation where the torque arm applied to the table saw is too large when supporting heavy workpieces and the saw table is tilted can be avoided. In embodiments where support legs are provided, the support legs may be fixed to the extension rail in a position relative to the extension working surface, or alternatively may be connected to the extension working surface via hinges or pivot pins. In still other embodiments, the support legs may be completely separable from the extension working surface. That is, the support legs may be a separate component that can be added to the extension working surface to provide support between the rail and the ground.

[0034] In some embodiments, the extension assembly may include one or two support legs, thereby supporting the extension working surface and extension rails while the extension assembly is attached to the table saw. With three or more legs, the extension working surface can be used as a standalone worktable without requiring expanded capacity and can be attached to the table saw.

[0035] The extension tracks can be connected to the main track or to each other via a connector assembly. The connector assembly is configured to connect the extension tracks end-to-end to the main track so as not to interfere with the travel and function of the railing. Additionally, the connector assembly is configured such that the faces of the tracks that engage and guide the railing are aligned and coplanar with each other, and that the railing contact surfaces of each track are aligned, thereby allowing the railing to travel smoothly and locking squares at each position of the railing along the track assembly. The connector assembly includes: a latch plate, which is fixed to the end surface of one of the tracks to be connected (e.g., the main track); and a hook, which is fixed to the end surface of the other track to be connected (in this example, the extension track). Each of the latch plate and the hook is coupled to the inner surface of the respective track to avoid interference with the railing and reduce tolerance overlap, thus achieving contact surface alignment only with wall thickness variance.

[0036] The extension rails are easy to use and can be quickly installed and removed without tools. To this end, the connector assembly includes a gravity pivot hook that reinforces the connection between the connected rails through gravity and loads on the extension rail and the extension working surface. Lifting the end of the extension rail counteracts gravity and allows for its removal. In some embodiments, a locking function is provided to prevent accidental lifting and removal of the extension rail.

[0037] The extension rail can be installed on either side of the table saw. For example, the extension rail can be positioned on the left or right side of the saw table. Additional sections can be added to further increase saw capacity. Attached Figure Description

[0038] Figure 1 This is a perspective view of a portable table saw including its extension components.

[0039] Figure 2 yes Figure 1 A perspective view of a portion of the track assembly of a table saw, showing the connector assembly.

[0040] Figure 3 As seen from one angle. Figure 2 A partial exploded and magnified perspective view of a portion of the track assembly.

[0041] Figure 4 As seen from another perspective Figure 2 A partial exploded and magnified perspective view of a portion of the track assembly.

[0042] Figure 5 As seen from one angle. Figure 2 A fully exploded and magnified perspective view of a portion of the track component.

[0043] Figure 6 As seen from another perspective Figure 2 A fully exploded and magnified perspective view of a portion of the track component.

[0044] Figure 7 This is a side cross-sectional view of the connector assembly.

[0045] Figure 8 Is it like along Figure 7 The cross-sectional view of the connector assembly is shown in line 8-8.

[0046] Figure 9 Is it like along Figure 7 The cross-sectional view of the connector assembly is shown in line 9-9.

[0047] Figure 10 Is it like along Figure 7 The cross-sectional view of the connector assembly is shown in line 10-10.

[0048] Figure 11 Is it like along Figure 7 The cross-sectional view of the connector assembly is shown in line 11-11.

[0049] Figure 12 This is a perspective view of the latch plate of the connector assembly as seen from one angle.

[0050] Figure 13 This is a perspective view of the latch plate of the connector assembly, as seen from another angle.

[0051] Figure 14 This is a perspective view of the hook-shaped part of the connector assembly as seen from one angle.

[0052] Figure 15 This is a perspective view of the hook-shaped part of the connector assembly, as seen from another angle.

[0053] Figure 16 yes Figure 1 A schematic exploded front view of a table saw.

[0054] Figure 17 yes Figure 1 A schematic top view of a table saw.

[0055] Figure 18 This is a schematic exploded front view of an alternative embodiment of a table saw.

[0056] Figure 19 yes Figure 18 A schematic top view of a table saw.

[0057] Figure 20 This is a schematic exploded front view of another alternative embodiment of the table saw.

[0058] Figure 21 yes Figure 20 A schematic top view of a table saw.

[0059] Figure 22 This is a schematic exploded front view of another alternative embodiment of the table saw.

[0060] Figure 23 yes Figure 22 A schematic top view of a table saw. Detailed Implementation

[0061] refer to Figure 1 and Figure 16-17The portable table saw 1 includes a tabletop 6 supported on a wheeled, foldable frame 4. The tabletop 6 includes an upward-facing working surface 8 that supports the material being sawed (not shown). The working surface 8 includes a working surface opening 20, which is spaced apart from and surrounded by a peripheral edge 10. A blade 26 (e.g., a circular saw blade) of the portable table saw 1 protrudes through the working surface opening 20, and an insert 28 is disposed in the working surface opening 20 between the blade 26 and the working surface 8. A motor (not shown) is disposed within the tabletop 6 and configured to rotate the blade 26 within the working surface opening 20. The portable table saw 1 includes a guardrail 34 for guiding the material relative to the blade 26. The guardrail 34 can be supported relative to a table 2 on main rails 42, 52, which are disposed on opposite sides of the working surface 8. Specifically, the guardrail 34 extends above the working surface 8 and between opposite sides of the working surface 8. The guardrail 34 includes a guide surface 36 that is perpendicular to the table working surface 8 and aligned with the axis of rotation of the blade 26. In use, the material to be cut rests on the table working surface 8, adjacent to the guardrail guide surface 36. Cutting is performed by advancing the material against the blade 26, including sliding the material on the table working surface 8 and along the guardrail guide surface 36. To increase sawing capacity, the table saw 1 also includes an extension assembly 60 that can be easily attached to and detached from the table 2. The extension assembly 60 includes a pair of extension rails 62, 72 and an extension working surface 76 supported on the pair of extension rails 62, 72. The extension assembly 60 is supported on main rails 42, 52 such that the extension working surface 76 is coplanar with the table working surface 8, and each of the pair of extension rails 62, 72 extends continuously from the corresponding one of the main rails 42, 52, as discussed in detail below. In use, the guardrail 34 can be positioned relative to the table surface 8 by sliding the guardrail 34 along the main rails 42, 52 and the extension rails 62, 72 to the desired distance from the blade 26 and fixing the guardrail 34 in that position using a locking mechanism (not shown).

[0062] As used in this article, references to relative directions (such as top, bottom, upper, lower, upward, downward, above, below, over, under, overlying, lying down, horizontal, vertical, etc.) are relative to... Figure 1 The orientation of the portable table saw 1 shown is made by way of fact and is not intended to be limiting.

[0063] The platform 6 includes a housing 22 for receiving the motor and a platform working surface 8 resting on the housing 22. The outer edge 10 of the platform working surface 8 has a rectangular outline when viewed from above. Figure 16(Best viewed from the center), and includes a first side 12, a second side 14 connecting the first side 12, a third side 16 opposite to and parallel to the first side 12 and connecting the second side 14, and a fourth side 18 connecting the first side 12 and the third side 16 and parallel to the second side 14. The stage working surface 8 has a larger dimension than the housing 22, thereby positioning the first side 12, the second side 14, the third side 16 and the fourth side 18 of the peripheral edge 10 outward relative to the corresponding sides of the housing 22, and these four sides cooperate to support the stage working surface 8.

[0064] The first main track 42 and the second main track 52 are supported on the table surface 6. More specifically, the first main track 42 is supported on a first side 12 of the outer periphery edge 10 of the table working surface, and the second main track 52 is supported on a third side 16 of the outer periphery edge 10 of the table working surface. The first main track 42 and the second main track 52 are elongated hollow rigid structures with irregular cross-sectional profiles. Each of the first main track 42 and the second main track 52 includes a first end 44, an opposing second end 46, and a longitudinal axis 48 extending between the first end 44 and the second end 46. The first main track 42 and the second main track 52 are parallel to each other and extend parallel to the plane defined by the table working surface 8. The lengths of the first main track 42 and the second main track 52 (e.g., dimensions along a direction parallel to the longitudinal axis 48) correspond to the lengths of the first side 12 and the third side 16. In addition, each of the first main track 42 and the second main track 52 includes a main rail contact surface 50 facing away from the outer periphery edge 10 of the table surface 6. The main railing contact surface 50 has an irregular profile, which is configured to engage and slide relative to the corresponding track contact surface 38 of the railing 34. The main railing contact surface 50 faces away from and extends parallel to the first side 12 and the third side 16 of the countertop 6.

[0065] The extension assembly 60 includes a first extension rail 62 and a second extension rail 72 supporting an extended working surface 76. Additionally, the extension assembly 60 includes a first connector assembly 100 and a second connector assembly 102. The first connector assembly 100 mechanically connects the first extension rail 62 to a first main rail 42, and the second connector assembly 102 mechanically connects the second extension rail 72 to a second main rail 52.

[0066] The first extension track 62 and the second extension track 72 are elongated hollow rigid structures with irregular cross-sectional profiles. Each of the first extension track 62 and the second extension track 72 includes a first end 64, an opposing second end 66, and a longitudinal axis 68 extending between the first end 64 and the second end 66. Each of the first extension track 62 and the second extension track 72 includes an extension guardrail contact surface 70 having the same profile as the contact surfaces 50 of the first main track 42 and the second main track 52, which is configured to engage and slide relative to the corresponding track contact surface 38 of the guardrail 34.

[0067] The extended working surface 76 is a plate extending between the first extended track 62 and the second extended track 72. When the first extended track 62 and the second extended track 72 are assembled with the corresponding first main track 42 and second main track 52, the extended working surface 76 is coplanar with the stage working surface 8 and supports the material to be cut extending beyond the stage working surface 8. In the illustrated embodiment, the extended working surface 76 is provided as a single piece, and its length corresponds to or is slightly less than the lengths of the first extended track 62 and the second extended track 72. In other embodiments, the extended working surface 76 may be provided as a single piece with a relatively short length. In still other embodiments, the extended working surface 76 may be provided as multiple pieces spaced apart along the lengths of the first extended track 62 and the second extended track 72.

[0068] refer to Figure 2 and Figure 17 In use, the first extension rail 62 is connected to the first main rail 42 via the first connector assembly 100, such that a) the first main rail 42 and the first extension rail 62 are arranged end-to-end; b) the longitudinal axis 48 of the first main rail 42 is collinear with the longitudinal axis 68 of the first extension rail 62; and c) the main rail contact surface 50 of the first main rail 42 is aligned with the extension rail contact surface 70 of the first extension rail 62. Similarly, the second extension rail 72 is connected to the second main rail 52 via the second connector assembly 102, such that a) the second main rail 52 and the second extension rail 72 are arranged end-to-end; b) the longitudinal axis 48 of the second main rail 52 is collinear with the longitudinal axis 68 of the second extension rail 72; and c) the main rail contact surface 50 of the second main rail 52 is aligned with the extension rail contact surface 70 of the second extension rail 72.

[0069] refer to Figure 3-15 The first connector assembly 100 and the second connector assembly 102 are identical in form and function, and therefore only the first connector assembly 100 will be described in detail. The first connector assembly 100 includes a latch plate 110 and hooks 130 configured to engage with the latch plate 110.

[0070] A latch plate 110 is disposed on the end face of one of the main track and the extension track. For example, in the illustrated embodiment, the latch plate 110 is disposed on the end face 46a of the second end 46 of the first main track 42. The latch plate 110 includes a hook-facing surface 112 and a first track-facing surface 114, which faces and abuts the hook-facing surface 112 and is adjacent to the end face 46a of the second end 46 of the first main track. The hook-facing surface 112 and the first track-facing surface 114 are each planar and parallel to each other. The latch plate 110 includes a peripheral edge 116 that surrounds the latch plate 110 and extends between the hook-facing surface 112 and the first track-facing surface 114.

[0071] The outer edge 116 of the latch plate includes a latch plate guard contact surface 116a. When the latch plate 110 is fixed to the end face 46a, the latch plate guard contact surface 116a is continuous with the main guard contact surface 50.

[0072] The latch plate 110 includes a latch plate opening 118 that extends between the hook-facing surface 112 and the first track-facing surface 114 and is surrounded by a latch plate peripheral edge 116. The latch plate opening 118 is shaped and sized to receive a protrusion 160 of the hook 130 in a tolerance fit. In the illustrated embodiment, the latch plate opening 118 is rectangular in shape and elongated along a direction parallel to the first side 12 of the platform. Additionally, the latch plate 110 includes a through-hole 122 for receiving a fastener (not shown) that secures the latch plate 110 to the end face 46a of the first main track 42.

[0073] A hook 130 is disposed on the end face of the other of the first main track 42 and the first extension track 62. In the illustrated embodiment, the hook 130 is disposed on the end face 64a of the first end 64 of the first extension track 62. The hook 130 includes a mounting plate 132 and a fastener 150 assembled with the mounting plate 132. The fastener 150 engages with both the latch plate 110 and the first extension track 62, as discussed further below.

[0074] Mounting plate 132 includes a surface 134 facing the latch plate and a second surface 136 facing the track, the second surface facing the track being opposite to the surface 134 facing the latch plate and adjacent to the end face 64a of the first end 64 of the first extended track.

[0075] Mounting plate 132 includes a peripheral edge 138 that surrounds the mounting plate 132 and extends between a surface 134 facing the latch plate and a second surface 136 facing the track. The peripheral edge 138 includes a mounting plate guardrail contact surface 138a. When the mounting plate 132 is secured to end face 64a, the mounting plate guardrail contact surface 138a is continuous with the latch plate guardrail contact surface 116a and the extended guardrail contact surface 70.

[0076] Mounting plate 132 includes a mounting plate opening 148 that extends between a surface 134 facing the latch plate and a second surface 136 facing the track and is surrounded by a peripheral edge 138 of the mounting plate. The mounting plate opening 148 is shaped and sized to receive a protrusion 160 in a tolerance fit. In the illustrated embodiment, the mounting plate opening 148 is rectangular in shape and elongated along a direction parallel to the first side 12 of the platform. Additionally, mounting plate 132 includes a through-hole 142 for receiving fasteners (not shown) that secure mounting plate 132 to the end face 64a of the first end 64 of the first extended track 62.

[0077] The second track-facing surface 136 is planar. The lower portion 144 of the latch plate-facing surface 134 (e.g., the portion 144 of the latch plate-facing surface 134 surrounding the mounting plate opening 148) is planar and parallel to the second track-facing surface 136. The upper portion 146 of the latch plate-facing surface 134 is angled such that a gap 104 exists between the latch plate 110 and the mounting plate 132 at this location. The gap 104 facilitates the assembly of the latch plate 110 with the hook 130 by allowing the mounting plate 132 to be angled relative to the latch plate 110 while maintaining a tight proximity between the mounting plate 132 and the latch plate 110, as occurs during assembly.

[0078] The fastener 150 is a rigid member comprising a handle 140 and a protrusion 160 integrally projecting from the latch plate-facing surface of the handle 140. The handle 140 is an elongated rectangular prism along a direction parallel to the longitudinal axis 68 of the extension track 62. The insertion end of the handle 140 may be chamfered for easy assembly with the extension track 62. The handle 140 is sized such that it extends (e.g., horizontally) a distance parallel to the longitudinal axis 68 of the first extension track, a distance greater than the corresponding dimension of the protrusion 160. Additionally, the handle 140 extends vertically a distance slightly smaller than the corresponding dimension of the first extension track 62. The handle 140 fits tightly within an opening 64b provided in the end face 64a of the first extension track 62 to the extent that the second track-facing surface 136 abuts against the end face 64a of the first extension track 62. With this configuration, the handle 140 facilitates the hook 130 to be firmly and stably held on the first extended track 62.

[0079] The protrusion 160 is generally J-shaped and is sized to engage the latch plate 110. The protrusion 160 includes a base portion 162 connecting to the handle 140 and a lip portion 164 extending at an angle from the base portion 162. More specifically, the base portion 162 protrudes from the latch plate-facing surface of the handle 140 in a direction perpendicular to the latch plate-facing surface. The base portion 162 is sized sufficiently in a direction parallel to the longitudinal axis 68 of the first extension track to allow it to extend through both the mounting plate opening 148 and the latch plate opening 118. Additionally, the vertical dimension of the base portion is smaller than the vertical dimension of the handle 140. The lip portion 164 protrudes from the base portion 162 to extend in a direction parallel to the mounting plate 132 and toward the upper surface of the first extension track 62.

[0080] When the hook 130 is assembled with the latch plate 110, the base portion 162 of the protrusion 160 protrudes through the mounting plate opening 148 and the latch plate opening 118 and the lip portion 164, and engages the first track-facing surface 114 of the latch plate 110 such that the hook 130 is held on the latch plate 110, and the first extended track longitudinal axis 68 is coaxial with the main track longitudinal axis 48 and parallel to the plane defined by the table working surface 8.

[0081] In this configuration, the loads of the first extension rail 62 and the second extension rail 72, as well as the loads of any material supported on these structures, are transferred to the stage 2 via the location of the hook 130 contacting the latch plate 110. Specifically, the loads are transferred to three contact locations within the first connector assembly 100.

[0082] The first contact position corresponds to the location where a portion 162a of the protrusion 160 (e.g., the downward-facing surface 162a of the base portion 162) abuts the upward-facing portion 118a of the latch plate opening 118. At this first contact position, the weight of the first extension track 62 and the second extension track 72, the extended working surface 76, and any workpiece loads on top of them are transferred from the hook 130 to the latch plate 110.

[0083] The second contact position corresponds to the location where the portion 164a of the protrusion 160 facing the mounting plate (e.g., the portion 164a of the lip portion 164 facing the mounting plate) abuts a portion 114a of the first track-facing surface 114 of the latch plate 110. At this second contact position, axial loads and bending moments are transferred.

[0084] The third contact position corresponds to the location where a portion 134a of the mounting plate 132 facing the latch plate is adjacent to a portion 112a of the latch plate 110 facing the hook. At this third contact position, axial loads and bending moments are transferred. Additionally, providing a locating screw (not shown) in either contact surface at the third contact position provides adjustability in the alignment of the first main track 42 and the first extension track 62.

[0085] At each contact point, the load is transferred over a large surface area (e.g., the contact point is two-dimensional), thereby ensuring a reliable and stable connection between the latch plate 110 and the hook 130, and minimizing the relative movement between the latch plate 110 and the hook 130.

[0086] When the hook 130 is assembled with the latch plate 110 as described above, the mounting plate guardrail contact surface 138a is continuous with the latch plate guardrail contact surface 116a. As a result, the first main track 42, the first connector assembly 100 and the first extension track 62, and the second main track 52, the second connector assembly 102 and the second extension track 72 each cooperate to provide a continuous guardrail contact surface that extends along the entire length of the table and the extension assembly. This allows the guardrail 34 to be moved away from the blade 26 by a distance limited only by the lengths of the extension tracks 62 and 72.

[0087] The extension assembly 60 is assembled with and detached from the tabletop 6 by connecting the hooks 130 of each connector assembly 101, 102 to the corresponding latch plates 110. The method of forming a connection between the latch plates 110 and hooks 130 of the first connector assembly 101 is the same as the method of forming a connection between the latch plates 110 and hooks 130 of the second connector assembly 102; therefore, only the method of forming a connection between the latch plates 110 and hooks 130 of the first connector assembly 101 will be described. Disconnection is achieved by reversing this method.

[0088] The extension assembly 60 is assembled to the tabletop 6 using the following steps: The first extension track 62, including the hook 130, is held at an angle relative to the first main track 42, including the latch plate 110, and the lip portion 164 of the protrusion 160 is inserted into the latch plate opening 118. To achieve the angled position, the first end 64 of the first extension track 62 is positioned adjacent to and at the same height as the second end 46 of the first main track 42, and the second end 66 of the first extension track 62 is positioned higher than the first end 64. After the lip portion 164 is inserted into the latch plate opening 118, the first extension track 62, including the hook 130, is pivoted until the longitudinal axis of the first extension track 62 is aligned with the longitudinal axis of the first main track 42 (e.g., the second end 66 of the first extension track 62 is lowered). As a result, the hook 130 pivots relative to the latch plate 110 to a position in which the protrusion 160 protrudes through the latch plate opening 118 and the lip portion 164 engages with the first track-facing surface 114 of the latch plate 110. The gap 104 provides clearance in this connection to allow pivoting action.

[0089] Assembling the extension assembly 60 with the tabletop 6 is easily achieved without fasteners or tools. Furthermore, the effect of gravity on the extension assembly 60 provides a bending moment that holds the hook 130 onto the latch plate 110.

[0090] refer to Figure 16 and Figure 17 When the extension assembly 60 is connected to the second ends 46, 46 of the first main rail 42 and the second main rail 52, the extension assembly 60 is on one side of the tabletop 6 (e.g., the right side, relative to the tabletop 6). Figure 1 and Figure 16 The table saw, as illustrated in the diagram, extends from the table surface 6. In this configuration, the cutting dimension of the table saw 1 is increased compared to that without the extension.

[0091] refer to Figure 18 and Figure 19 An alternative embodiment of the table saw 200 includes an extension assembly 60 positioned on the other side of the tabletop 6 (e.g., the left side, relative to the tabletop 6). Figure 1 and Figure 18 (The table saw is oriented as shown in the diagram). This is achieved by the following steps: providing latch plates on the first ends 44, 44 of the first main rail 42 and the second main rail 52, and connecting the extension assembly 60 to the first ends 44, 44 of the first main rail 42 and the second main rail 52.

[0092] refer to Figure 20 and Figure 21Another alternative embodiment of the table saw 300 includes an extension assembly 60 (hereinafter referred to as "overhanging extension assembly 60") positioned on the right side of the table surface 6, wherein a supported extension assembly 360 is disposed between the table surface and the overhanging extension assembly 60. In this configuration, the supported extension assembly 360 connects the overhanging extension assembly 60 to the table surface 6 and increases the cutting size of the table saw 1 compared to the cutting size when the overhanging extension assembly 60 is used alone. The supported extension assembly 360 is similar to the overhanging extension assembly 60 described above, and common reference numerals will be used to refer to common elements. The supported extension assembly 360 includes a first extension rail 62' and a second extension rail 72' supporting an extended working surface 76'. Additionally, the supported extension assembly 360 includes a first connector assembly 100' and a second connector assembly 102'. The first connector assembly 100' mechanically connects the first extension rail 62' to the first main rail 42', and the second connector assembly 102' mechanically connects the second extension rail 72' to the second main rail 52'. In this embodiment, the first connector assembly 100 and the second connector assembly 102 of the cantilever extension assembly 60 are used to connect the cantilever extension assembly 60 to the end of the supported extension assembly 360 opposite to the table surface 6. In this configuration, the table working surface 8, the supported extension working surface 76', and the cantilever extension working surface 76 are coplanar and provide a substantially continuous surface on which material can rest. In addition, the guardrail contact surfaces 50, 50 of the first main rail 42 and the second main rail 52, the guardrail contact surfaces 70', 70' of the first extension rail 62' and the second extension rail 72' of the supported extension assembly 360, and the guardrail contact surfaces 70, 70 of the first extension rail 62 and the second extension rail 72 of the cantilever extension assembly 60 are substantially continuous.

[0093] The supported extension assembly 360 differs from the cantilever extension assembly 60 in that it includes at least one support leg 362 extending between the ground 3 (e.g., the "support surface") and the working surface 76' of the supported extension assembly 360. In the illustrated embodiment, the supported extension assembly 360 includes two legs (only one is shown) 362, each leg 362 positioned at a location spaced apart from the tabletop 6, for example adjacent to the second end 66' of the corresponding first extension rail 62' and second extension rail 72'.

[0094] refer to Figure 22 and Figure 23Another alternative embodiment of the table saw 400 includes a cantilever extension assembly 60 disposed on the right side of the tabletop 6 and a supported extension assembly 360 disposed on the left side of the tabletop 6. In this configuration, the cutting size of the table saw 1 is increased compared to when the cantilever extension assembly 60 is used alone. As in the previous embodiment, the table working surface 8, the supported extension working surface 76', and the cantilever extension working surface 76' are coplanar and provide a substantially continuous surface on which material can rest. In addition, the guardrail contact surfaces 50, 50 of the first main rail 42 and the second main rail 52, the guardrail contact surfaces 70', 70' of the first extension rail 62' and the second extension rail 72' of the supported extension assembly 360, and the guardrail contact surfaces 70, 70 of the first extension rail 62 and the second extension rail 72 of the cantilever extension assembly 60 are substantially continuous.

[0095] The configuration of the cantilever extension assembly 60 and / or the supported extension assembly 360 relative to the tabletop 6 is not limited to the embodiments described above. For example, it is contemplated that the supported extension assembly 360 can be connected to the tabletop 6 without omitting the cantilever extension table (not shown).

[0096] Although in the illustrated embodiment the cantilever extension assembly 60 and / or the supported extension assembly 360 are held connected to the tabletop 6 only via connector assemblies 100, 102, 100', 102', the table saw is not limited to this configuration. For example, in some embodiments, a locking mechanism (not shown) may be used in conjunction with connector assemblies 100, 102, 100', 102' to secure the cantilever extension assembly 60 and / or the supported extension assembly 360 to the tabletop 6.

[0097] Although frame 4 includes a foldable tubular support structure in the illustrated embodiment, in other embodiments, frame 4 may include a set of four conventional legs or cabinets. In still other embodiments, frame 4 may be omitted, and the tabletop 6 may be placed on a conventional table.

[0098] In the illustrated embodiment, hook 130 is an assembly of fastener 150 and mounting plate 132. However, it should be understood that hook 130 may be formed as an integral structure, wherein fastener 150 and mounting plate 132 are integrally formed.

[0099] In the illustrated embodiment, the latch plate 110 includes a latch plate opening 118 that extends between the hook-facing surface 112 and the first track-facing surface 114 and is surrounded by a latch plate peripheral edge 116. However, the latch plate 110 is not limited to this configuration. For example, in some embodiments, the latch plate 110 may be a smaller, opening-free plate that only covers a portion of the track opening end. In other embodiments, the latch plate 110 may be replaced by another type of fastening mechanism (such as a pin with a square or circular cross-section) that engages the hook 130.

[0100] The foregoing has described selective illustrative embodiments of a portable table saw in considerable detail. It should be understood that only the structures necessary to illustrate certain features of the table saw have been described herein. Other conventional structures of the portable table saw, as well as accessories and auxiliary components, are assumed to be known and understood by those skilled in the art. Furthermore, although working examples of the portable table saw have been described above, the portable table saw is not limited to the working examples described above, but various design changes can be implemented without departing from the portable table saw as set forth in the claims.

Claims

1. A connector assembly configured to connect one end of a first rail to one end of a second rail, the connector assembly comprising: a latch plate disposed on an end face of one of the first rail and the second rail, the latch plate comprising: a hook-facing surface; a first rail-facing surface opposite the hook-facing surface and abutting the end face of the one of the first rail and the second rail; and a latch plate opening extending between the hook-facing surface and the first rail-facing surface; and a hook protruding from an end face of the other of the first rail and the second rail, the hook comprising a mounting plate and a curved protrusion protruding from the mounting plate, the mounting plate being secured to the end face of the other of the first rail and the second rail, the mounting plate having: a latch plate-facing surface; and a second rail-facing surface opposite the latch plate-facing surface and abutting the end face of the other of the first rail and the second rail; the protrusion protruding from the mounting plate, extending through the latch plate opening, and engaging the first rail-facing surface of the latch plate, wherein the protrusion engages the first rail-facing surface of the latch plate such that the hook is retained on the latch plate, and a longitudinal axis of the second rail is parallel to a longitudinal axis of the first rail.

2. The connector assembly of claim 1, wherein, the protrusion is configured such that, when the protrusion is engaged with the latch plate, a portion of the mounting plate abuts a portion of the latch plate and a portion of the protrusion abuts a portion of the latch plate opening.

3. The connector assembly of claim 2, wherein the portion of the mounting plate, the portion of the latch plate, the portion of the protrusion, and the portion of the latch plate opening each comprise a two-dimensional surface.

4. The connector assembly of claim 1, wherein, the protrusion is configured such that, when the protrusion is engaged with the latch plate, a portion of the latch plate-facing surface of the mounting plate abuts a portion of the hook-facing surface of the latch plate, a mounting plate-facing portion of the protrusion abuts a portion of the first rail-facing surface of the latch plate, and a portion of the protrusion abuts a portion of the latch plate opening.

5. The connector assembly of claim 1, wherein, the latch plate-facing surface of the mounting plate comprises an angled portion, whereby a gap exists between the latch plate and a portion of the mounting plate.

6. The connector assembly of claim 1, wherein, the hook comprises an assembly of the mounting plate and a catch, wherein the catch comprises the protrusion.

7. A table saw comprising: a table work surface comprising an opening configured to receive a cutting blade, and a first side, a second side, a third side, and a fourth side surrounding the table work surface; a main rail supported on the first side; an extension assembly comprising an extension rail and a connector assembly configured to couple the extension rail to the main rail, a fence supported on one of the main rail and the extension assembly so as to be slidable relative to the table surface, wherein the connector assembly comprises: a latch plate disposed on an end face of one of the main rail and the extension rail, the latch plate comprising: a hook-facing surface; a first rail-facing surface opposite the hook-facing surface and abutting the end face of the one of the main rail and the extension rail; and a latch plate opening extending between the hook-facing surface and the first rail-facing surface; and a hook protruding from an end face of the other of the main rail and the extension rail, the hook comprising a mounting plate secured to the end face of the other of the main rail and the extension rail, the mounting plate having: a latch plate-facing surface; and a second rail-facing surface opposite the latch plate-facing surface and abutting the end face of the other of the main rail and the extension rail; the protrusion protruding from the mounting plate, extending through the latch plate opening, and engaging the first rail-facing surface of the latch plate, wherein the protrusion engages the first rail-facing surface of the latch plate such that the hook is retained on the latch plate, and a longitudinal axis of the extension rail is parallel to a plane defined by the table work surface.

8. The table saw of claim 7, wherein, a longitudinal axis of the extension rail is parallel to a longitudinal axis of the main rail.

9. The table saw of claim 7, wherein, the protrusion is configured such that, when the protrusion is engaged with the latch plate, a portion of the mounting plate abuts a portion of the latch plate and a portion of the protrusion abuts a portion of the latch plate opening.

10. The table saw of claim 9, wherein the portion of the mounting plate, the portion of the latch plate, the portion of the protrusion, and the portion of the latch plate opening each comprise a two-dimensional surface.

11. The table saw of claim 7, wherein, the protrusion is configured such that, when the protrusion is engaged with the latch plate, a portion of the latch plate-facing surface of the mounting plate abuts a portion of the hook-facing surface of the latch plate, a portion of the protrusion-facing portion of the protrusion abuts a portion of the first rail-facing surface of the latch plate, and a portion of the protrusion abuts a portion of the latch plate opening.

12. The table saw of claim 7, comprising an extension work surface supported on the extension rail so as to be coplanar with the table work surface.

13. The table saw of claim 12, wherein the table work surface is supported relative to a support surface via a support structure, and the extension assembly comprises a support leg connected to the extension work surface and configurable to extend between the extension rail and the support surface.

14. The table saw of claim 7, wherein, the extension rail overhangs from the main rail via the connector assembly.

15. The table saw of claim 7, wherein the main rail is a first main rail and the table saw comprises a second main rail supported on a third side of the table work surface, the extension rail is a first extension rail and the extension assembly comprises a second extension rail, The connector assembly is a first connector assembly coupling the first extension rail to the first main rail, and the extension assembly includes a second connector assembly coupling the second extension rail to the second main rail, The second connector assembly includes: a latch plate seated on an end face of one of the second main rail and the second extension rail; and a hook protruding from an end face of the other of the second main rail and the second extension rail, the hook including a curved protrusion, wherein the protrusion engages a rail-facing surface of the latch plate such that the hook is retained on the latch plate, and a longitudinal axis of the second main rail is parallel to a longitudinal axis of the second extension rail.

16. The table saw of claim 15, comprising an extension work surface supported on the first extension rail and the second extension rail so as to be coplanar with the table work surface.

17. A table saw, comprising: a table work surface including an opening configured to receive a cutting blade, and a first side, a second side, a third side, and a fourth side surrounding the table work surface; a main rail supported on the first side; an extension assembly including an extension rail and a connector assembly configured to couple the extension rail to the main rail, a fence supported on one of the main rail and the extension assembly so as to be slidable relative to the table surface, wherein the connector assembly includes: a latch plate seated on an end face of one of the main rail and the extension rail, the latch plate including a latch plate opening; and a hook protruding from an end face of the other of the main rail and the extension rail, the hook including a mounting plate fixed to the end face of the other of the main rail and the extension rail, and a curved protrusion protruding from the mounting plate, extending through the latch plate opening, and engaging a rail-facing surface of the latch plate, wherein the protrusion engages the rail-facing surface of the latch plate such that the hook is retained on the latch plate, and a longitudinal axis of the extension rail is parallel to a plane defined by the table work surface, wherein: the main rail and the extension rail each include a contoured surface configured to engage a rail-contacting surface of the fence, a peripheral edge of each of the latch plate and the mounting plate includes a contoured portion having a same contour as the contoured surface of the main rail and the extension rail, and the contoured portions of the peripheral edges of the latch plate and the mounting plate cooperate with the contoured surfaces of the main rail and the extension rail to provide a continuous fence-contacting surface configured to enable the fence to slide along both the main rail and the extension rail.

18. A table saw kit, comprising: a table saw; and an extension table, wherein the table saw includes: ​ a table work surface comprising an opening configured to receive a cutting insert; a first main rail supported on a first side of the table work surface; a second main rail supported on a second side of the table work surface, wherein the second side is on an opposite side of the table work surface from the first side; and a fence mounted on the first main rail and the second main rail so as to be slidable relative to the table work surface, the extension table comprises: a first extension rail; a second extension rail extending parallel to the first extension rail, an extension work surface extending between and supported on the first extension rail and the second extension rail such that the extension work surface is coplanar with the table work surface, a first connector assembly configured to connect the first extension rail to the first main rail; a second connector assembly configured to connect the second extension rail to the second main rail; wherein the first connector assembly and the second connector assembly each comprise: a latch plate seated on an end face of one of the main rail and the extension rail, the latch plate comprising: a hook facing surface; a first rail facing surface opposite the hook facing surface and abutting the end face of the one of the main rail and the extension rail; and a latch plate opening extending between the hook facing surface and the first rail facing surface; and a hook protruding from an end face of the other of the main rail and the extension rail, the hook comprising a mounting plate fixed to the end face of the other of the main rail and the extension rail and a curved protrusion protruding from the mounting plate, the mounting plate having: a latch plate facing surface; and a second rail facing surface opposite the latch plate facing surface and abutting the end face of the other of the main rail and the extension rail; the protrusion protrudes from the mounting plate, extends through the latch plate opening, and engages the first rail facing surface of the latch plate, wherein the protrusion engages the first rail facing surface of the latch plate such that the hook is retained on the latch plate, and a longitudinal axis of the extension rail is parallel to a plane defined by the table work surface.

19. The table saw kit of claim 18, wherein, the extension table overhangs from the table saw via the first and second connector assemblies.

20. The table saw kit of claim 18, wherein the extension table is connected to the table saw via the first and second connector assemblies, the table work surface is supported relative to a support surface via a support structure, and the extension table comprises a support leg connected to the extension work surface and configurable to extend between the extension work surface and the support surface.

21. The table saw kit of claim 18, wherein the extension table is an overhanging extension table overhanging from the table saw via the first and second connector assemblies, The table saw kit includes a supported extension table including: a third extension rail; a fourth extension rail extending parallel to the third extension rail, a supported extension work surface extending between and supported on the third extension rail and the fourth extension rail such that the supported extension work surface is coplanar with the table work surface, a support leg connected to the supported extension work surface and configurable to extend between the supported extension work surface and a support surface, a third connector assembly configured to connect the third extension rail to one of the first main rail and the first extension rail; a fourth connector assembly configured to connect the fourth extension rail to one of the second main rail and the second extension rail.

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