BACKGROUND OF THE INVENTION Field of the Invention The present invention relates to a sawhorse.
A sawhorse is a movable frame or trestle for supporting wood or another work-piece while it is being sawed or for supporting plates to provide working spaces. With their wide base, sawhorses provide stable support for a work-piece. Traditionally sawhorses were made of wood or metal, however, following the technological progress of the plastic industry, sawhorses are nowadays also available from plastic materials. The present invention provides several improvements over the prior art.
SUMMARY OF THE INVENTION One aspect of the present invention provides a sawhorse. The sawhorse includes a pair of identical support members, and a connector structure. Each support member includes a pair of spaced apart legs, and an upper work surface for supporting a work-piece. The upper work surface being integrally formed with the legs. Each support member includes an integrally formed hinge portion directly connectable with the hinge portion of the other support member. The connector structure is arranged to connect an intermediate portion of the support members to one another.
These and other aspects of the present invention, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the invention. As used in the specification and in the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.
BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side view of a sawhorse in an operative position in accordance with an embodiment of the present invention;
FIG. 2 is a perspective view of a support member with a connector structure attached to the support member in accordance with an embodiment of the present invention;
FIG. 3 is a perspective view of a plurality of hinge members, including a plurality of projections and a plurality of openings, in accordance with an embodiment of the present invention;
FIG. 4 is a top view of two support members being offset with respect to each other before being connected to each other in accordance with an embodiment of the present invention;
FIG. 4a is a partial cross-section view of the two support members shown in FIG. 4 in accordance with an embodiment of the present invention;
FIG. 5 is a top view of two, offset support members being pushed towards each other to connect the two support members with each other in accordance with an embodiment of the present invention;
FIG. 5A is a partial cross-section view of the two support members shown in FIG. 5 in accordance with an embodiment of the present invention;
FIG. 6 is a top view of two support members sliding against each other to connect the two support members in accordance with an embodiment of the present invention;
FIG. 6a is a partial cross-section view of the two support members shown in FIG. 6 in accordance with an embodiment of the present invention;
FIG. 7 is a side view of the sawhorse in folded position, in which the connector structure is shown (partially in phantom lines) in accordance with an embodiment of the present invention;
FIG. 8 is a side view of the sawhorse in an operative position with the connector structure being moved from a folded position to an operative position in accordance with an embodiment of the present invention;
FIG. 9 is a side view of the sawhorse in the operative position with the connector structure being moved from the folded position to the operative position in accordance with an embodiment of the present invention;
FIG. 10A is a cross-section view of the connector structure attached to one support member in accordance with an embodiment of the present invention;
FIG. 10B is a partial perspective view of the connector structure with a pin and engagement members in accordance with an embodiment of the present invention; and
FIG. 11 is a perspective view of the releasable connection between the connector structure and the other support member in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION FIG. 1 shows a sawhorse 10 in accordance with an embodiment of the present invention. The sawhorse 10 may generally include a pair of identical support members 12 and 14, and a connector structure 16. Each support member 12 or 14 includes a pair of spaced apart legs 18 and 20 (as shown in FIG. 2), and an upper work surface 22 for supporting a work-piece (not shown). The work surface 22 is integrally formed with the legs 18 and 20. Each support member 12 or 14 includes an integrally formed hinge portion 24 directly connectable with the hinge portion 24 of the other support member 14 or 12 respectively. The connector structure 16 is arranged to connect an intermediate portion 26 of the support members 12 and 14 to one another.
The sawhorse 10 may be configured to move between a folded position (as shown in FIG. 7) to an operative position (as shown in FIG. 1). In the operative position, the sawhorse 10 is configured to support work-pieces or plates that provide working spaces. In the operative position, the first and the second support members 12 and 14 are diverging (e.g., outwardly and downwardly) away from each other to form an A-shaped structure. In this operative position, the support members 12 and 14 are pivoted to an unfolded or expanded configuration. The extent of unfolding may be limited by interengaging surfaces between the support members 12 and 14, such as toward the hinge portions 24, or by the connector structure 16. In the operative position, in one embodiment, the work surfaces 22 of each support member 12 and 14 may include portions 68 thereof that lie in substantially the same plane to define a two-portion planar work surface. Such planar work surface defined by surfaces 68 may be substantially horizontal when the support members 12 and 14 are unfolded or expanded to the configuration illustrated in FIG. 1. In addition work surfaces 22 may additionally provide a pair of surface portions 70 (one on each support member 12 and 14) that together define a 90° V-shaped notch disposed to receive the orthogonal surfaces of a work-piece (such as the corner of a 2′×4′ piece of wood). The sawhorse 10 may be moved into the folded position simply by pivoting the connector structure 16 about hinge 44 (by moving hinge 44 upwards), and then by manipulating the sawhorse 10 so that the first and the second support members 12 and 14 pivot about the hinge portion 24 and come in close proximity to each other due to gravity or by manually pivoting them closed. In another embodiment, the sawhorse 10 may be moved into the folded position by releasing the connector structure 16 from the intermediate portion 26 of the support member 14, and then manually folding the sawhorse 10 to bring the first and the second support members 12 and 14 come in close proximity to each other (e.g., see FIGS. 8 and 9). In the folded position, the first and the second support members 12 and 14 are generally placed in a side by side contacting relation with each other to form a compact structure that may easily be transported from one place to another or stored.
Also, as will be clear from the discussions later with respect to FIGS. 7, the first and the second support members 12 and 14 may easily be disconnected from each other, thus, enabling the first and the second support members 12 and 14 to be stored separately. The first and the second support members 12 and 14 that are stored separately may easily be connected back to each other, without the need for any tools or additional fasteners.
The first and second support members 12, 14 are each individual integral structures and are generally each made of a suitable molded plastic (e.g., by injection molding). As the first and the second support members 12, 14 can be formed from the same mold, the first and second support members 12, 14 are generally identical to each other.
FIG. 2 shows the first support member 12, which includes the pair of spaced apart leg members 18, 20, the upper work surface 22, the intermediate portion 26, and the plurality of integrally formed hinge portion 24. In one embodiment, the spaced apart leg members 18, 20 may generally be parallel to each other. In another embodiment, the spaced apart leg members 18, 20 may generally be angularly diverging (e.g., outwardly, downwardly or otherwise) with respect on each other. In one embodiment, each leg member 18 or 20 may generally include a C-shaped or channel cross-sectional configuration. It should be appreciated, however, that this is but one example of different types of leg member shapes, configurations and/or constructions that can be provided.
In one embodiment, the thickness of each leg member 18 or 20 may increase as the leg member 18 or 20 joins an upper member 62. In one embodiment, the thickness of each leg member 18 or 20 may increase near the lower free end 152 thereof so as to provide stability and balance to the sawhorse 10 when the sawhorse 10 is in the operative position.
The upper member 62 is a cross member that connects the leg members 18 and 20 at an upper portion thereof. The intermediate portion 26 (“intermediate portion” refers herein to a region on the legs 18, 20 between the free ends 152 and the hinge portion 24) of each leg member 18, 20 defines a region that includes some structure that allows a connector structure to be connected thereto. As one example, the intermediate portion 26 of the legs 18, 20 may accommodate a cross-member 29 as shown in FIG. 2. This is but one example, and in another arrangement, any structure, pin, opening or connector can be provided at the intermediate portions 26 to permit a connection therebetween. The cross member 29 or other structure may optionally be considered to be part of the intermediate portions 26. However, the connector structure 16 can take any form to prevent spreading of the support members 12, 14 or additional structural support for support members 12, 14 and need not utilize cross member 29 for accomplishing this. In addition there is no need for connector structure 16 to be able to provide any support surface for supporting articles, although it is an option to provide such connector structure 16 with such article supporting functionality.
In one embodiment, the upper member 62, the cross member 29, and the leg members 18 and 20 define an opening 64 therebetween. In one embodiment, the opening 64 may be configured to receive the connector structure 16, when placed in a folded configuration (as shown in FIG. 7). In one embodiment, a structure 200 that includes a pair of inwardly protruding members is located on each leg member 18 or 20 to support a cord. In one embodiment, the structure 200 is in the form of a hook.
The hinge portion 24 may be located along the length of the upper member 62. The hinge portion 24 may include a plurality of first hinge members 102 and a plurality of second hinge members 104, as seen in FIG. 3. In one embodiment, the plurality of first hinge members 102 may include projections 28, and the plurality of second hinge members 104 may include openings 30. In one embodiment, the first hinge members 102 with the projections 28, and the second hinge members 104 with the openings 30 are spaced apart alternatively along the length of each support member 12 or 14. In the illustrated embodiment, a group of first hinge members 102 with the projections 28 that are spaced apart from each other are followed by a group of second hinge members 104 with the openings 30 that are spaced apart from each other. The spacings may generally be equidistant in one embodiment.
In one embodiment, the hinge portion 24 (e.g., with the openings 30 and with the projections 28) are integrally molded with the inner surface 66 of the upper portion 62 of the first support member 12. In another embodiment, as noted above, the integrally molded hinge portion 24 may be accommodated in a notch 65.
The upper work surface 22, for supporting a work-piece (not shown), is also integrally formed with the legs 18 and 20 of the support members 12 or 14 in the upper portion 62 thereof. The upper work surface 22 may optionally include the two separate portions 68 and 70, so that the two support members 12, 14 can provide both a planar work surface portion as well as a notched 90° work surface portion. The horizontal surface 68, the angular surface 70 and an adjacent vertical surface 72 may be joined to each other along the length of their adjacent edges. Referring back to FIG. 1, when the sawhorse 10 is in the operative position, the vertical surface 72 of the first support member 12 is placed in a side by side contacting relation with the vertical surface 72 of the second support member 14. In this embodiment, the surfaces 72 may operate as stop surfaces to limit the amount of outward expansion of the support members 12, 14. In one embodiment, the surfaces 72 are disposed at a right angle (90°) with respect to the surfaces 68. When the sawhorse 10 is placed in the operative position, the angular surface 70 of the first support member 12 and the angular surface 70 of the second support member 14 together form the 90° V-shaped notch 76 as previously described. When the sawhorse 10 is placed in the operative position, the angular surfaces 70 and the horizontal surfaces 68 are configured to support the loads applied by a work-piece (not shown).
In one embodiment, as shown in FIG. 2, the upper work surface 22 may include one or more transverse notches 74 located in the upper work surface 22. In the illustrated embodiment, the upper work surface includes two notches 74. The notches 74 may be configured to support and secure a work-piece on a lateral cut-out surface 75 of the upper work surface 22. In another embodiment, the upper work surface 22 may include only one notch or may not include notches. Similarly the work surface 22 may only include the planar work surface formed by surfaces 68, or only the V-shaped notch 76.
Referring to FIGS. 1 and 2, the connector structure 16 includes a first portion 40 and a second portion 42. The first portion 40 of the connector structure 16 may be foldably attached (as will be seen in FIG. 7) to the second portion 42 by the hinge 44. The operation of the connector structure 16 between a folded position (as shown in FIG. 7) and an operative position (as shown in FIG. 1) will be clear from the discussions with respect to FIGS. 8-11.
As shown in FIG. 2, the second portion 42 of the connector structure 16 includes peripheral wall portions 48 and 50, an inwardly sloping wall portion 52 and a support surface 54. The peripheral wall portions 48 and 50 are attached on either side of the second portion 42. The inwardly sloping wall portion 52 is disposed along a portion of the second portion 42 on a side that is away from the hinge 44. The peripheral wall portions 48 and 50 and the inwardly sloping wall portion 52 are configured to surround the support surface 54 along three sides of the second portion 42 to define an area 58 to support articles, such as tools, or the like. As shown in the illustrated embodiment, the second portion 42 may include an opening 56 located on the support surface 54. The structure of the first portion 40 of the connector structure 16 is the same as the structure of the second portion 42, and hence will not be discussed in detail here. However, in one embodiment, the way in which the first portion 40 is connected to the support member 12 or 14 is different from the way in which the second portion 40 is connected to the support member 14 or 12, as will be explained in the discussions later with respect to the FIGS. 8-11.
In one embodiment, as shown in FIG. 2, the hinge 44 of the connector structure 16 may include a plurality of cylindrical members 76 and a plurality of hollow members 78 integrally formed on the first portion 40, and a plurality of cylindrical members 76 and a plurality of hollow members 78 integrally formed on the second portion 42. In the illustrated embodiment, the plurality of cylindrical members 76 and the plurality of hollow members 78 that located on the first portion 40 or the second portion 42 are constructed and arranged such that a group of cylindrical members 76 are followed by a group of hollow members 78. In another embodiment, the plurality of cylindrical members 76 and the plurality of hollow members 78 located on the first portion 40 are constructed and arranged such that cylindrical member 76 and hollow member 78 are placed alternatively along the length of the first portion 40 or the second portion 42. The plurality of cylindrical members 76 on one portion 40 or 42 are configured to connect with the plurality of hollow members 78 on the other portion 42 or 40 to foldably and pivotably connect the first portion 40 and the second portion 42. In this embodiment, the cylindrical members 76 may include solid cylindrical cross-section. In another embodiment, the hinge 44 may include a plurality of cylindrical members 76 integrally formed on both the first portion 40 and the second portion 42. In this embodiment, the first portion 40 and the second portion 42 are foldably and pivotably connected to each other using a pin (not shown), which passes through an opening (not shown) in the cylindrical members 76 to foldably and pivotably connect the first portion 40 and the second portion 42. It should be appreciated, that different types of hinge shapes, configurations and/or constructions are contemplated as long as the hinge 44 foldably and pivotably connects the first portion 40 with the second portion 42.
As the structure and construction of the second support member 14 is identical to the structure and construction of the first support member 12, the structure and construction of the second support member 14 is not discussed in detail here. However, the connection between the intermediate portion 26 of the second support member 14 and the connector structure 16 is different from the connection between the intermediate portion 26 of the first support member 12 and the connector structure 16, as will be explained in the discussions later with respect to the FIGS. 10 and 11.
FIG. 3 shows the detailed view of the hinge portion 24 integrally formed on the first support member 12. As noted above, in one embodiment, the hinge portion 24 includes the plurality of first hinge members 104 with the openings 30, and the plurality of second hinge members 102 with projections 28. Each first hinge member 104 may be in the form a boss with opening 30 extending therethrough in a side portion thereof. Each second hinge member 102 may include a connector member 106 and the projection 28. The projection 28 is constructed and arranged to be extending from the connector member 106 in a side portion thereof. In the illustrated embodiment, the connector member 106 may be in the form of a boss. The projections 28 and the openings 30 attached to the first support member 12 are configured to engage with the openings 30 and projections 28 on the second support member 14 to connect the first and second support members 12 and 14. In one embodiment, each projection 28 is formed on the first support member 12 at the connector member 106. In one embodiment, the projections 28 and the openings 30 formed on first support member 12 are spaced apart so that the openings 30 and the projections 28 attached to the second support member 14 are configured to fit therebetween.
FIGS. 4-6A show the process of connecting two identical support members 12 and 14 of the sawhorse 10 with each other. As shown in FIGS. 4 and 4A, the first support member 12 and the second support member 14 are longitudinally offset by a distance A with respect to each other so that the first hinge members 102 are configured to be received in spaces 114 between two consecutive second hinge members 104, or the second hinge members 104 are configured to be received in spaces 112 between two first hinge members 102. Once the first support member 12 and the second support member 14 are offset with respect to each other, the first support member 12 and the second support member 14 are moved or pushed towards each other in the direction of the arrow A as shown in FIGS. 5 and 5A. When the first support members 12 and the second support member 14 are pushed towards each other, each second hinge member 104 is configured to be received in the space 112 between two first hinge members 102, and/or each first hinge member 102 is configured to be received in the space 114 between two consecutive second hinge members 104. After the first hinge members 102 and the second hinge members 104 are received in the spaces 114 and 112 respectively, the first support member 12 and the second support member 14 are slid in opposite direction as shown with an arrow B away from each other as shown in FIGS. 6 and 6A. The sliding movement of the first support member 12 against the second support member 14 causes the projections 28 of the first hinge members 102 to be received in the openings 30 of the second hinge members 104, thus, connecting the first support member 12 and the second support member 14.
In one embodiment, the projections 28 are received in openings 30 with little frictional engagement therebetween. In another embodiment, a friction fit may be formed, wherein the friction nevertheless permits frictionally damped pivoting movement. In another embodiment, the projections 28 may form a snap type connection with openings 30.
In one embodiment, when connector structure 16 is connection between the intermediate portions 26 (e.g., via cross member 29), the connector structure 16 can serve to prevent relative longitudinal displacement between the two support members 12, 14 so as to prevent the projections 28 from being moved out from openings 30.
FIG. 7 shows the sawhorse 10 in the folded position with the first support member 12 and the second support member 14 connected to each other. In this embodiment, the connector structure 16 is in folded position and is shown partially in phantom lines.
Referring FIGS. 4-7, in one embodiment, the sawhorse 10 may be disassembled easily (after the connector structure 16 is disconnected, in one embodiment) by sliding the first support member 12 and the second support member 14 in opposite directions (e.g., in a direction opposite to arrow B in FIG. 6). When the first support member 12 and the second support member 14 are slid in opposite directions (e.g., in the direction opposite to arrow B in FIG. 6), the projections 28 and the openings 30 on the first support member 12 are disengaged from the corresponding openings 30 and projections 28 on the second support member 14. After the projections 28 and the openings 30 on the first support member 12 are disengaged from the corresponding openings 30 and projections 28 on the second support member 14, the first support member 12 and the second support member 14 are moved apart from each other and stored separately. When a user wants to use the sawhorse 10, the first support member 12 and the second support member 14 may be easily connected back to each other, as explained in detail with respect to FIGS. 4-6A, without the need for tools or additional parts (e.g., fasteners).
FIGS. 8 and 9 show the sawhorse 10 in the operative position and the connector structure 16 being moved from the folded configuration to an operative configuration. The connector structure 16 is pivotally connected between the intermediate portions 26 of the first and second support members 12 and 14. In one embodiment, the connector structure 16 is operatively associated with the support members 12 and 14 such that movement of the sawhorse 10 between its folded and operative positions moves the connector structure 16 between the folded position and the operative position.
In the operative position, as shown in FIG. 1, the first portion 40 and the second portion 42 of the connector structure 16 generally lie in a same plane to provide a flat surface 46 (e.g., a shelf) to support the plurality of articles, such as tools or the like. When placed in operative position, the connector structure 16 also limits or prevents any lateral movement between the support members 12 and 14.
When the connector structure 16 is in the folded position (as shown in FIG. 7), the first portion 40 and the second portion 42 are generally disposed in side-by-side contacting relation to each other. In one embodiment, the first portion 40 and the second portion 42 are generally disposed parallel to each other.
In one embodiment, as shown in FIG. 10A, the first portion 40 of the connector structure 16 is permanently connected to the intermediate portion 26 (e.g., cross member 29 thereof) of the first support member 12 using a pin 120. As shown in the illustrated embodiment, the first support member 12 may include an opening 122 to accommodate the pin 120, thus, attaching the first portion 40 to the intermediate portion 26 of the first support member 12. In one embodiment, the connector structure 16 may include two pins 120 that are located on each side of the first portion 40 of the connector portion 16 to attach the connector structure 16 to the cross member 29 of the intermediate portion 26. In one embodiment, the first portion 40 of the connector structure 16 may include a plurality of attachment members 86 that are constructed and arranged to connect the first portion 40 of the connector structure 16 with the intermediate portion 26 (e.g., cross member 29 thereof). FIG. 10B shows a partial perspective view of the connector structure 16 with the attachment member 86 and the pin 120 that are used to attach the first portion 40 of the connector structure 16 to the cross member 29 of the intermediate portion 26 (as shown in FIG. 10A). It should be appreciated, however, that this embodiment is but one example of different types of retainer or fastening structure shapes, configurations and/or constructions that can be provided. In another embodiment, the first portion 40 of the connector structure 16 is permanently connected to the intermediate portion 26 of the first support member 12 by other fastening mechanisms as would be appreciated by one skilled in the art.
As shown in FIG. 11, the second portion 42 of the connector structure 16 is releasably connected to the intermediate portion 26 (e.g., cross member portion 29 of intermediate portion 26) of the second support member 14 by a snap connection. The second portion 42 includes an end 80 that is away from the hinge 44. The end 80 of the second portion 42 includes a plurality of mating members 82, which are configured to engage with a plurality of engaging members 84 on the cross member portion 29 of intermediate portion 26 of the second support member 14. In one embodiment, each mating member 82 may include a bent (e.g., hook-shaped) portion 86. The engaging member 82 is integrally formed on the cross member portion 29 of intermediate portion 26. In one embodiment, each engaging member 84 of the cross member portion 29 of intermediate portion 26 is in the form of a solid cylindrical member 88, that are separated from one another by a plurality of ribs 90. The plurality of bent portions 86 are separated from each other by a recess 92 having a length d that is slightly more than the length of the separation ribs 90. Each cylindrical member 88 of the cross member portion 29 of intermediate portion 26 is configured to engage with the bent portion 86 of the mating member 82, and each rib 90 is configured to engage with the recess 92 to releasably connect the second portion 42 of the connector structure 16 with intermediate portion 26 of the second support member 14 by a snap connection. It should be appreciated, however, that this embodiment is but one example of different types of mating and engaging member shapes, configurations and/or constructions that can be provided. It is contemplated that a pin and a hole connection, a hook and a loop connection, friction fit or other releasably connections as would be appreciated by one skilled in the art may be used to connect the second portion 42 of the connector structure 16 with the intermediate portion 26 of the second support member 14.
Although in the illustrated embodiment discussed above, the connector structure 16 is permanently attached to the first support member 12 and releasably connected to the second support member 14, it is contemplated that in another embodiment the connector structure 16 may be permanently attached to both support members 12, 14 by a pin as previously described to prevent disassembly by the user. In another embodiment, the connector structure 16 is releasably attached to both support members 12, 14 as previously described.
In one embodiment, the entire structure associated with first support member 12 is integrally molded as a single or unitary plastic piece, including the upper work surface 22 thereof, including the hinge portion 24 thereof, and the legs 18, 20 thereof. The same is true for the identically formed second support member 14.
Although the invention has been described in detail for the purpose of illustration based on what is currently considered to be the most practical and preferred embodiments, it is to be understood that such detail is solely for that purpose and that the invention is not limited to the disclosed embodiments, but, on the contrary, is intended to cover modifications and equivalent arrangements that are within the spirit and scope of the appended claims. For example, it is to be understood that the present invention contemplates that, to the extent possible, one or more features of any embodiment can be combined with one or more features of any other embodiment.
