Foldable sawhorse

Abstract

Embodiments of a foldable sawhorse are shown and described, which may be collapsed to a very flat shape, with one of the leg frames fitting inside the central open area of the other so that the two leg frames are co-planar. This way, the two leg frames preferably do not contact each other except at their mutual pivot point(s), and they do not interfere with each other. Preferably, the bottom surfaces of all portions of the sawhorse that touch the ground are broad, smooth, substantially continuous across the whole width of the sawhorse. The bottom surfaces preferably have no protrusions, such as feet, that might promote sinking into the ground or catching excessively on the ground/floor. The preferred sawhorse has one or more platforms that are fixedly attached to their respective parts of the sawhorse in such ways and in such angles that their top platform surfaces are level with the ground or other supporting surface when the sawhorse is unfolded.

Description

DESCRIPTION

[0001] This application claims priority of my prior provisional application, Serial No. 60/198,858, filed Apr. 21, 2000, entitled “Foldable Sawhorse.”

BACKGROUND OF THE INVENTION

[0002] 1. Field of the Invention

[0003] The present invention relates, generally, to folding sawhorses. More particularly, the invention relates to a folding saw horse that has a thin profile when folded. The folding sawhorse also has a system for allowing easy movement of the sawhorse on the ground or shop floor, and may also has supporting platforms at two levels relative to the ground.

[0004] 2. Related Art

[0005] Several folding sawhorses are discloses in the prior art. Such sawhorses include: U.S. Pat. No. 5,078,352 (Brow); U.S. Pat. No. 5,560,448 (Yemini); U.S. Pat. No. 5,560,449 (Smith); U.S. Pat. Nos. 5,647,455 (Russell); and 5,839,540 (Russell). Typically, conventional foldable sawhorses are bulky when folded because the two legs can pivot together, at most, an amount that places the feet together but maintains a V-shape, as shown in FIGS. P-A, P-B, P-C, and P-D.

[0006] FIGS. P-A is a side view of the prior art sawhorse in an unfolded position, and FIGS. P-B is a side view of the prior art sawhorse in a folded position. One may see that the unfolded sawhorse takes the shape of a wide-spread V with thickness T1, and the folded sawhorse still retails the shape of a V, albeit a more narrow one. Although the prior art sawhorse's two leg frames pivot on a single axis at the top of the sawhorse, the leg frames get in each other's way when folded, so that a V-shape with a thickness T2 equal to at least the sum of the thicknesses of each leg.

[0007] Typically, these prior art sawhorses have four feet that protrude downward from the legs and/or the transverse members at the bottom end of the sawhorse, wherein the transverse members are only for reinforcement rather than for providing a surface for ground contact. The conventional feet may be seen to best advantage in FIGS. P-C, a front perspective view of the prior art sawhorse in the unfolded position, and FIGS. P-D, a front view of the folded sawhorse. The feet tend to poke into, or excessively frictionally engage, the ground or other surface upon which the sawhorse stands. These relatively small conventional sawhorse feet tend to dig into, or shift unpredictably on, dirt or gravel, making them unsafe in many circumstances. Also, because the feet dig into or grip the ground, the sawhorse is difficult to move, either when one needs to move it for improved positioning during use or for transport to an alternative work location or for storage.

SUMMARY OF THE INVENTION

[0008] The present invention includes a foldable sawhorse with two leg frames that are pivotally connected. The sawhorse includes leg frames that may be called rectangular or U-shaped and are pivotally connected together at their top ends. The invented sawhorse includes a platform connected to the top ends of the leg frames in a position that places its flat top surface parallel to the ground or surface upon which the sawhorse is placed, when the sawhorse is unfolded. The two leg frames are adapted so that one of the leg frames pivots into the other, so that the two leg frames lie on the same plane when the sawhorse is folded (“collapsed”). This way, the sawhorse folds into a very thin, compact shape for carrying or storage.

[0009] Preferably, the adaptation that allows the sawhorse to collapse to a very flat shape and yet to have horizontal platform(s) when unfolded involves having an asymmetrical structure. Preferably, one leg frame is larger than the other, so that the smaller leg frame fits completely inside the larger leg frame when the sawhorse is collapsed. Platform attachment and positioning is adapted to cooperate with this asymmetrical structure to provide horizontal upper surfaces for support of objects during use of the sawhorse.

[0010] The two leg frames preferably include elongated, solid members as the bottom members that rest on the ground or other surface. These bottom members preferably extend across the entire width of the sawhorse with no significant protrusions, to present a solid, smooth, continuous, substantially horizontal surface for the sawhorse to rest on. This way, the sawhorse may rest in a secure and stable position on a wide variety of surfaces, even slightly uneven surfaces, and is not likely to suddenly shift position, tip, or slant. Also, the preferably-horizontal bottom member surface provides a smooth and broad surface for contact with the ground, concrete, or other support surface, so that the invented sawhorse does not sink into the support surface, and may be easily slid along the support surface when desired. This way, it is easy to adjust the exact location of the sawhorse relative to equipment or work-pieces, or to slide the sawhorse across a shop floor or construction site.

[0011] Preferably, one or more securement members are included to limit leg frame movement to the desired open, unfolded position when in use. For example, chains or other flexible tie members may be included on the sawhorse, to connect the first leg frame to the second leg frame, preferably at two positions about half way down the leg frames on the left side and the right side of the sawhorse.

[0012] The first leg frame is preferably generally a rectangle with an open space between a bottom bar which serves as the above-mentioned bottom member, and two side bars. The second leg frame is also generally rectangular, with a bottom member for placement on the ground or support surface (that is, a first horizontal or transverse member), two side members preferably pivotally connected at their top to the first leg frame. Preferably, the second leg frame also has a second horizontal or transverse member connected the two side members to further strengthen and rigidize the second side frame. Preferably, this second transverse member connects the side members at about midway down the second leg frame.

[0013] The second leg frame to pivotally attached inside the first leg frame and is smaller in width and in length than the first leg frame, so that the second leg may pivot into, and lie in the same plane, as the first leg frame. Because the second leg frame is shorter than the first leg frame, measured from the top end of the sawhorse at the connection point(s) of the two leg frames, the top platform must be attached to the sawhorse so that the plane of its top surface is non-normal (as well as non-parallel) to the plane of the folded legs. This way, when the sawhorse is unfolded, the plane of the top platform moves to horizontal to provide a flat horizontal surface for supporting workpieces, tools, boards, etc..

[0014] Optionally, the sawhorse may include a second platform, preferably generally mid-way down on the sawhorse. Preferably, the second platform is part of, or acts as, a second transverse member of the second leg frame for strengthening and rigidizing the second leg frame. The second platform is connected to the sawhorse in a manner that places the top surface of the second platform horizontal when the sawhorse is unfolded. Typically, this may be done by connecting the second platform so that its top surface is slightly angled relative to horizontal when the sawhorse is folded (and held vertical as in FIG. 5), and, in effect, the platform position moves to horizontal when the sawhorse is unfolded and set up with legs separated.

[0015] The invented foldable sawhorse provides surprising stability during use, even though its pivotal leg portions are not the same length and the top platform is not centered over the depth of the legs (from bottom end of the one leg to the bottom end of the other leg D). The inventor has found that symmetry is not necessary, that this asymmetrical sawhorse is extremely stable, and the asymmetry allows for a very compact collapsed device for storage and transport.

BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIGS. P-A is a side view of one prior art foldable sawhorse, in an unfolded, set-up position.

[0017] FIGS. P-B is a side view of the prior art sawhorse of FIGS. P-A, in a folded position.

[0018] FIGS. P-C is a front, perspective view of the sawhorse of FIGS. P-A and P-B, in the unfolded position.

[0019] FIGS. P-D is a front view of the saw horse of FIGS. P-A, B, and C, in the folded position.

[0020] FIG. 1 is a front view of one embodiment of the invented foldable sawhorse with a single platform.

[0021] FIG. 2 is a left end view of the embodiment of FIG. 1, in a collapsed (folded) position.

[0022] FIG. 3 is a left end view of the embodiment of FIGS. 1 and 2 in an extended (unfolded) position.

[0023] FIG. 4 is a front end view of an alternative embodiment of the invention with two platforms, one on top of the sawhorse and one approximately mid-way down one leg frame.

[0024] FIG. 5 is a right end view of the embodiment of FIG. 4, showing the oppositely-slanted positions of the top and middle platform that are necessary to place the platform top surfaces flat and horizontal when the sawhorse is opened (unfolded) on a horizontal surface G.

[0025] FIG. 6 is a right end view of the embodiment of FIGS. 4 and 5, unfolded with the result of level horizontal platforms.

[0026] FIG. 7 is a front view of an alternative view of the invented sawhorse with a telescoping leg frame feature.

[0027] FIG. 8a is a front, partial view of one embodiment of a connection system having clamp members for connecting a transverse member to a leg frame of the invention. FIG. 8b is a top, partial view of the connection system of FIG. 8a, with the clamp members loosened for illustration.

DETAILED DESCRIPTION OF THE INVENTION

[0028] Referring to the Figures, there is shown one embodiment of a prior art sawhorse, and three embodiments of the invented sawhorse 10, 10′, 10″. In FIGS. 1-3, there is shown a one-platform sawhorse 10 with first leg frame 12 and second leg frame 14 pivotally connected at a single axis 60. First leg frame 12 is made of top member or top pipe 16, right and left side members or pipes 18, 20 which are welded or otherwise attached at their top ends to top pipe 16 at connections 22. The bottom ends of the right and left pipes are welded or otherwise attached to a transverse bottom pipe 26 at the outer ends of the pipe 26 at connections 30. The bottom surface 34 of bottom pipe 26 is preferably a smooth, continuous surface substantially all the way across the width W of the sawhorse. Preferably, this bottom surface 34 is the rounded, cylindrical surface of the cylindrical bottom pipe 26. Preferably, there are no feet or other protrusions from the bottom surface 34 at any location that would touch the ground G or other surface on which the sawhorse sets in the unfolded, and even the folded, positions.

[0029] Preferably the first leg frame 12 is rigidly and non-pivotally connected to the top platform 40, with the platform 40 being attached to top pipe 16 such that its top surface 42 is an a slight angle relative to level (horizontal) when the sawhorse is folded and positioned vertically. (FIG. 2). The angle is determined by the relative length of the first leg frame 12 and the second leg frame 14, as discussed below, and angle (A) when the sawhorse is setup. The angle of the platform top surface 42 relative to the plane of the first leg frame 12 is set so that, when the sawhorse is unfolded, as in FIG. 3, the top surface 42 is level. Thus, one may see that a typical angle, but not the only operable one, is about 20-25 degrees from horizontal in FIG. 2.

[0030] The second leg frame 14 has a shorter length L2 than the length L1 of the first leg frame 12. The second leg frame 14 is preferably made of a right and left side pipe 48 and 50 that are welded, integrally, or otherwise attached to pivoting sleeves 52 with interior hollow spaces that pivotally receive the top pipe 16. The bottom ends of the right and left side pipes 48 and 50 are welded or otherwise attached to a bottom member or pipe 56 that is parallel to pipe 26 and pipe 16 and platform 40. As with the first leg frame 12 bottom pipe bottom surface 34, pipe 56 has a bottom surface 58, that is, the entire portion of the pipe 56 that touches the ground when unfolded that is smooth, broad, and free of downward or other protrusions that would catch or dig into the ground.

[0031] Preferably, the generally rectangular leg frame 12 is four-sided, with the top side (top pipe 16 with platform 40) pivotally receiving the second leg frame. Preferably, the generally rectangular leg frame 14 is three-sided and attached at its top end (for example, the top ends of its legs) to the first leg frame 12. Second leg frame 14 may also include transverse member 66 or other non-transverse members for strengthening. Second leg frame 14 is also narrower than first leg frame 12, and generally rectangular, as is leg frame 12. Therefore, with this system, one may see that the second leg frame 14 may pivot to a folded position, in which the generally rectangular leg frame 14 fits inside the first leg frame 14 and is coplanar with the first leg frame. Also, the second leg frame 14 pivots out to the position in FIG. 3, in which, being the shorter leg frame, it causes the pivot axis 60 to not be centered over the bottom pipes of the leg frames but shifted to the right in FIG. 3. In other words, the pivot axis 60 and platform 40 are not equidistant from the bottoms of the two leg frames, and are not equidistant to the vertical planes passing up through the bottom pipes. Still, the top surface 42 is level because of the special slanting attachment of the platform 40. Preferably, the platform does not and need not pivot or move relative to first leg frame 12.

[0032] A chain 62 or other strong, secure limit or lock mechanism may be used to limit the amount of pivot of the leg frames relative to each other. This limit or lock may take the form of a connector between the two leg frames (such as chain 62) or, less preferably, may be a feature incorporated into the pivot mechanism that limits the amount of pivot of the leg frames relative to each other. Optionally, the limit or lock mechanism may lock the sawhorse, so that the leg frames will not pivot toward each other during use, unless the user purposely unlatches/unlocks the mechanism. Because the weight of objects on the sawhorse during use will tend to keep the sawhorse from collapsing, the preferred lock or limit does not need to make the sawhorse nonpivoting.

[0033] A stop 67 is preferably included to limit movement of leg frame 14 relative to leg frame 12, when the sawhorse is collapsed. Stop 67 prevents second leg frame 14 [does not] from swinging all the way through the first leg frame, but instead stops in the plane of the first leg frame 12. Stop 67 may protrude up from bottom pipe 26 at an outer side of the pipe 26, so that second leg frame hits, and is limited from further movement past, the stop 67 when the sawhorse is collapsed.

[0034] In the preferred embodiment, both stop 67 and chain 62 serve to control the pivoting of the leg frames relative to each other. Without stop 67 and chain 62, second leg frame (given the preferred connection by slidable/rotatable sleeve 52) would swing 360 degrees relative to the first leg frame around the sawhorse's single axis.

[0035] Preferably, the various pipes/legs/transverse members are cylindrical and straight, but other members may be used, as long as their strength and lightness are appropriate, and as long as the surfaces 34, 58 are smooth, broad, long; straight, and non-biting into the support surface. The smooth, wide bottom surfaces 34 and 58 create an easily-movable sawhorse 10 that does not sink into the ground G and tends to slide smoothly along the support surface (G) when the user purposely moves it. This is beneficial to workiman, mechanics, and other users, as described in the Summary. While welding or other attachment means may be used, the various transverse members and vertical members may be formed in part or entirely by bending of pipe.

[0036] Another embodiment is shown in FIGS. 4-6, which includes a plurality of platforms. This sawhorse 10′ is preferably built like the one described in FIGS. 1-3, but it includes an additional platform 70 on second leg frame 14. Second platform 70 is transverse, that is, perpendicular to the right and left side pipes 48, 50, and is preferably rigidly connected to the transverse member 66 so that its flat upper surface 72 is horizontal when the sawhorse is setup. Second platform 70 fits preferably between pipes 48, 50 and is shorter than the width of the open space “O”. In FIGS. 5 and 6, one may see an embodiment in which the second platform 70 is connected to the second, shorter leg frame, and has a top surface that is at an angle non-normal and non-parallel to the second leg frame plane and that is non-parallel to the top surface of the first platform. The second platform top surface is at an angle of approximately 30-35 degree relative to the first (top) platform surface, or typically within a range of about 25-40 degrees depending upon the preferred geometry of the relative lengths of the first leg frame and second leg frame and the angle of the leg frames when opened. Alternatively, the second platform may take the place of the rigidizing/reinforcing transverse pipe 66, rather than being attached to the pipe 66.

[0037] To provide for the upper surface 72 being level when the sawhorse is unfolded, as in FIG. 6, the second platform 70 is attached to the member 66 so that its plane is at an angle slightly off from perpendicular to the plane of the second leg frame 14. In other words, the second platform is slanted in an opposite direction to the first platform, as may be seen in FIG. 5, and the two angles of the first platform 40 and the second platform 70 may be calculated by geometry calculations based on the angle of the first leg frame and second leg frame when in the unfolded position and the relative lengths of the first leg frame and second leg frame.

[0038] The platform(s) may be attached to the sawhorses by conventional fasteners. For example, nut and bolt and lock washer combinations may be used at several places along the length of the platforms to attach the platforms to the top pipe 16 and the transverse member 66. The bolts (not shown) may pass all the way through the pipe 16 and member 66 in positions that do not interfere with the use and movement of the sawhorse.

[0039] One may note that top platform 40 is attached to top pipe 16 in such a way that it does not significantly interfere with the pivoting of the two leg frames relative to each other. For example, there may be one or more washers or other spacers (not shown) placed between the top pipe 16 and the platform 40, for example, at locations 72 to create a slight distance between the pipe 16 and the platform 40 to leave room for pivoting of the sleeves 52 on the pipe 16. These spacers may be washers used on bolts that attach the platform to the pipe 16, for example.

[0040] Optionally, as illustrated in FIG. 7, each of the leg frame (12, 14) of an alternative sawhorse 10″ may include a telescoping feature, to lengthen and shorten the leg frames. Such a feature allows the sawhorse to, in effect, be made taller or shorter, to adjust the height of the platform(s), preferably with both leg frames being adjusted to maintain the top platform level with horizontal. The feature may include telescoping structure 80 on each vertical pipe (18, 20, 48, 50), wherein the lower portion 82 of the first leg frame slides toward and away from the upper portion 84 of the first leg frame. Also, the lower portion 86 of the second leg frame slides toward and away from the upper portion 88 of the second leg frame. A securement system 90 is included preferably on each pipe (18, 20, 48, 50) to firmly and surely anchor the portions of the leg frames to each other once their height has been selected.

[0041] Various systems may be used for connecting the various pipe/members together in various embodiments of the invention. An especially-preferred connection system for connecting transverse member 66 to the second leg frame features adjustable connection of both ends of the transverse member 66 to the leg frame. Adjustability may either be incremental, or, preferably, continuous vertically up and down the leg frame. As illustrated in FIGS. 8a and 8b, the transverse member may be connected to the vertical pipes 48 and 50 (one end of the transverse member and pipe 48 only are shown in FIGS. 8a and 8b) by means of a movable/removable clamp system 90. The clamp system 90 on each end of member 66 may comprise two brace members 92, 92′ that each have a first portion 93 that extends circumferentially around its vertical pipe 48, 50 and a second portion 95 that extends inward horizontally and axially along a length of the transverse member 66. The first and second portions are curved appropriately to approximately match the radius of the pipe and the radius of the transverse member 66, and are sized so that the brace members 92, 92′ come near to each other but do not reach other when tightened around the pipe and transverse member. Thus, by tightening the two brace members together, for example, by bolt 97, the brace members clamp around the transverse member 66 and the pipe 48, 50 to securely hold the member 66 at the desired height relative to the top pipe and the bottom members. Then, if desired, the user may loosen the bolt 97 to loosen the brace members 92, 92′ for adjusting the transverse member (in the clamp system 90) up or down on the second leg frame, and then the user may re-tighten the clamp system. In addition, there may be set screws 98 installed through the first portion 93 and the second portion 95 to further secure the brace member(s) to the vertical pipes and the transverse members and prevent vertical shifting of the vertical pipe relative to the clamp or horizontal shifting of the transverse member relative to the clamp.

[0042] Although this invention has been described above with reference to particular means, materials and embodiments, it is to be understood that the invention is not limited to these disclosed particulars, but extends instead to all equivalents within the broad scope of this description.

Claims

1. A foldable sawhorse comprising:

a first leg frame in a first plane and a second leg frame in a second plane;

the first leg frame and second leg frame pivotally connected together at a single axis passing through said first plane and through said second plane, wherein the first leg frame and second leg frame pivot apart to an open position for use and pivot together to a collapsed position for storage;

the first leg frame having a bottom member, two side members, and an open interior space between the bottom member and the single axis;

the second leg frame pivotal into the first plane to be co-planar with the first leg frame and fitting entirely into the open interior space when the sawhorse is in the collapsed position.

2. A foldable sawhorse as in claim 1, wherein:

the first leg frame is generally rectangular, having a length and a width, wherein the two side members are generally perpendicular to the bottom member to surround and define the open interior space; and

the second leg frame is generally rectangular, having a length and a width;

and wherein the second leg frame width is less than the width of the first leg frame and wherein the second leg frame length is less than the length of the first leg frame, so that the second leg frame fits entirely into the open interior space.

3. A foldable sawhorse as in claim 1, wherein the second leg frame has a bottom frame member and the sawhorse further comprises a first platform connected to and parallel to the single axis so that a top surface of the first platform is horizontal when the first leg frame and second leg frame are pivoted to the open position and their bottom members are rested on a generally horizontal surface.

4. A foldable sawhorse as in claim 3, wherein the first platform top surface is at a non-normal angle to the first plane.

5. A foldable sawhorse as in claim 3, wherein the first leg frame has a length between the first leg frame bottom member and the single axis, wherein the second leg frame has a length between the second leg frame bottom member and the single axis that is greater than the length of the first leg frame; and wherein, when the sawhorse is in the open position with said bottom members resting on said generally horizontal surface, the first platform is nearer to a vertical plane passing through the bottom member of the second leg frame than it is to a vertical plane passing through the bottom member of the first leg frame.

6. A foldable sawhorse as in claim 3, further comprising a second platform attached to the second leg frame, parallel to the single axis, and generally midway between the single axis and the bottom member of second leg frame.

7. A foldable sawhorse as in claim 6, wherein the first platform top surface is at an angle to the first plane and wherein the second platform has a top surface that is at a non-normal angle to it the second plane, that is generally horizontal when the sawhorse is opened and the bottom members are resting on said generally horizontal surface, and that is at about 25-40 degrees to the first platform top surface when the sawhorse is in the collapsed position.

8. A foldable sawhorse as in claim 1, wherein the second leg frame has a bottom member and two side members, and the second leg frame bottom member and the first leg frame bottom member are straight, cylindrical pipes adapted to lie horizontally on a ground surface when the sawhorse is in the open position.

9. A foldable sawhorse as in claim 8, wherein there are no downward protrusions from the cylindrical pipes.

10. A foldable sawhorse as in claim 1, further comprising a chain connecting the first leg frame and second leg frame to limit pivoting of said leg frames relative to each other.

11. A foldable sawhorse as in claim 1, wherein the first leg frame and the second leg frame each have a telescoping mechanism for lengthening and shortening the first leg frame and the second leg frame.

12. A foldable sawhorse as in claim 1, wherein the second leg frame has a top end at the single axis and a bottom member, and further comprises a transverse member connected to the second leg frame between the single axis and the bottom member.

13. A foldable sawhorse as in claim 12, wherein said transverse member of the second leg frame is connected to the second leg frame by a adjustable connection system wherein the transverse member may be secured in a variety of locations up and down the leg frame.

14. A foldable sawhorse comprising:

a first leg portion with a top end and a bottom end and a length between the top end and bottom end, and having a second leg portion with a top end and a bottom end and a length between the top end and the bottom end, wherein the first leg portion and the second leg portion are pivotally connected together at an axis and pivotal apart to an open position and pivotal together to a collapsed position;

a platform connected to the sawhorse at the axis;

wherein the first leg portion length is longer than the second leg portion length so that, when the foldable sawhorse is in the open position, said bottom ends rest on a generally horizontally surface, and the platform is positioned over the bottom ends nearer the bottom end of the second leg portion.

15. A foldable sawhorse as in claim 14, wherein the first leg portion is a U-shaped frame and the second leg portion is a u-shaped frame having a smaller width and smaller length than the first leg portion, so that the second leg portion pivots into the first leg portion to be co-planer with the first leg portion.