STATION USING THE SAME

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention generally relates to portable work stations and, more

specifically, to a collapsible sawhorse suitable for creating stable workstations that can be quickly and easily assembled in the field.

2. Description of the Prior Art

Frequently workers in the construction trades at construction sites and DYI people around their homes need to use a temporary workstation, indoors or outdoors, for performing various construction and other tasks, such as cutting sections of lumber or other materials, measuring such items or performing any other functions that require materials to be supported on a surface or off the ground for convenient handling of materials and/or tools. Traditionally, fixed construction sawhorses have been used for this purpose, these generally being A- frame configurations made of wood, metal or plastic that are rigidly formed. The use of two such sawhorses spaced in generally parallel relationship to each other defines a plane that can support a flat section of lumber, such as a sheet of plywood, to form a work surface. However, such sawhorses have the disadvantage that, while they are helpful when in use, they are difficult to transport and inconvenient to store as a result of their bulky nature. This becomes especially problematic when such sawhorses need to be shipped, transported in a small vehicle, stored in a small residence or are used only occasionally. Also, because conventional sawhorses are rigid and do not have an adjustable leveling mechanism obtaining a stable and level horizontal work surface can be problematic because of irregularities on the ground when these are used outdoors.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the invention to provide a sawhorse that does not have the disadvantages or drawbacks of known prior art sawhorses.

It is another object of the invention to provide a sawhorse that is simple in construction and economical to manufacture.

It is still another object of the invention to provide a sawhorse that can be quickly and conveniently assembled in the field.

It is yet another object of the invention to provide a sawhorse of the type under discussion that provides a stable and reliable work surface.

It is a further object of the invention to provide a sawhorse as in the previous objects that can easily and conveniently be adjusted to compensate for variations on the ground or support surface.

It is still further object of the invention to provide a sawhorse as suggested in the previous objects that can be quickly and easily collapsed when no longer needed to be used for transportation and/or storage.

It is yet a further object of the invention to provide a sawhorse of the type under discussion that can provide level and reliable work surfaces of any size in the. field.

It is an additional object of the invention to provide a sawhorse as in the previous objects that includes support tabs or members on selected legs thereof for supporting a workpiece, such as a sheet of plywood, sheetrock or glass, for marking or cutting to minimize risk of injury to the user or damage to the workpiece.

It is yet an additional object of the invention to provide a workstation and method of assembling same using the sawhorses of the invention.

In order to achieve the above objects, and others that will become apparent hereinafter, a collapsible sawhorse in accordance with the present invention comprises a support member having a predetermined width and lateral free ends. A pair of legs are pivotally mounted proximate each lateral free end and movable between a collapsed condition in which each pair of legs are received within and substantially coextensive with said support member and an extended condition in which each pair of legs are pivoted from said collapsed condition to positions forming angles equal to at least 90° with associated lateral free ends. Each pair of legs has free ends in said extended condition that are spaced from each other along directions substantially normal to said longitudinal directions of said support members. Such pairs of legs form a four-point support base. Adjustment means are preferably provided for selectively adjusting the lengths of at least some of said legs in the extended conditions thereof to compensate for variations in elevation or irregularities in a support surface or ground to thereby enable said lateral free ends to be arranged in positions in a common essentially horizontal plane. Each lateral free end is provided, when in an expanded condition, with an upwardly open recess or notch for receiving an elongated support beam in a direction substantially normal said support members. In this manner, alignment of two spaced collapsible sawhorses can receive two spaced substantially parallel support beams essentially in a horizontal plane for supporting a flat panel placed on said support members and said support beams to maintain the flat panel in a substantially horizontal plane to provide a horizontal work surface in the field despite any irregularities in the support surface or ground on which said spaced sawhorses are positioned.

BRIEF DESCRIPTION OF THE DRAWINGS

Those skilled in the art will appreciate the improvements and advantages that arise from the present invention upon reading the following detailed description, claims and drawings, in which:

Fig. 1 is a side elevational view of one embodiment of a sawhorse in accordance with the present invention, shown in a fully collapsed condition;

Fig. 2 is a side elevational view of the sawhorse shown in Fig. 1 in which the support member is shown in an extended operative position, one leg assembly being shown in an extended operative position and the other leg assembly in the process of being moved to its extended operative position;

Fig. 3 is a perspective view of two sawhorses of the type shown in Figs. 1 and 2, spaced from each other in parallel relationship, for receiving spaced elongated support beams within upwardly open receiving recesses at lateral ends for supporting flat support member such as a sheet of plywood;

Fig. 4 is a perspective view of the sawhorses shown in Fig. 3 after the support beams and a flat support member have been placed on the sawhorses to form a workstation;

Fig. 5 is a side elevation view of another embodiment of the invention with a support member that is a continuous rigid member, in which the legs have progressed to different stages of extended positions; Fig. 6 is a side elevational view, partially broken away, of the sawhorse shown in Fig. 5, shown with the right leg assembly fully collapsed and received within the support member while the left leg has been partially extended to an intermediate position prior to being placed in its fully extended operative position;

Fig. 7 is a perspective view of the left end of the sawhorse shown in Figs. 5 and 6, showing some details of the mechanism for pivotally supporting the legs and for moving the legs and beam support brackets between contracted and extended positions

Fig. 8 is a perspective view illustrating the end structure for receiving a support beam at the right end of the sawhorse show in Fig. 7 after the associated legs have been moved to a partially extended position;

Fig. 9 is a side elevational view of the right end of the sawhorse shown in Fig.8, partially in cross-section, after the legs and beam support bracket has been moved to its fully expanded position;

Fig. 10 is a perspective view of the right end of the sawhorse shown in Fig. 9;

Fig. 1 1 is a perspective view of the sawhorse shown in Figs. 5-10 shown with both sets of legs in their lowered positions and with the right set of legs fully expanded to their operative positions;

Fig. 12 is a perspective view showing the various components forming the workstation in an exploded condition prior to assembly;

Fig. 13 is similar to Fig. 12 after the support beams have been placed into the lateral recesses of the workhorses and prior to placement of the flat support surface on the support beams; Fig. 14 is similar to Fig. 13 after the flat sheet of surface material has been placed on the support beams to form a workstation similar to the one shown in Fig. 4;

Fig. 15 is an enlarged view, in perspective, of a pivotally mounted support tab or member suitable for supporting a workpiece, on a lower portion of a leg, that needs to be measured, cut or the like;

Fig. 16 is a perspective view of a sawhorse in accordance with the invention in the fully extended, operative condition with the support tabs or members extended for supporting a flat sheet material in a partially vertical or inclined plane for measuring, cutting or the like;

Fig. 17 is a side elevational view of still another embodiment of the invention in which the lateral or side L-shaped brackets are not coupled to the legs for shared movements but the legs and the brackets can be independently extended and retracted as needed;

Fig. 18 is an enlarged sectional view of the left side of the saw horse shown in Fig. 17, showing details of the manner in which the legs and the lateral brackets are mounted for independent movements; and

Figs. 19 and 20 are perspective views of the saw horse of Figs. 17 and 18, showing how the lateral brackets can be selectively extended or retracted as may be required.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now specifically to the Figures, in which identical or similar parts will be designated by the same reference numerals throughout, and first referring to Fig. 1 , a first, embodiment of the sawhorse in accordance with the present invention is generally designated by the reference numeral 10.

The sawhorse 10 is a collapsible sawhorse that is formed of two arms 12a, 12b that are pivoted to each other by means of a pivot 14 and have edges 16a, 16b that are offset from each other by 180° in the collapsed condition of the arms and by 0° in the extended condition of the arms, as shown in Figs. 1 and 2.

Each of the arms 12a, 12b has one pivoted end, as shown, and free ends 18a, 18b formed with generally rectangular openings, notches or recesses 20a, 20b that are open in directions generally normal to the length directions of the associated arms.

When fully collapsed, each of the arms 12a, 12b receives associated pairs of collapsed legs 22a, 22b, respectively, at least some of the legs preferably being formed of telescoping leg portions so that each of the legs can be made longer or shorter as needed. The legs 22a include upper and lower leg portions 22a', and 22a" while the legs 22b include upper and lower leg portions 22b', 22b". Suitable detents or locking mechanisms well known to those skilled in the art are used to fix the relative positions of the telescoping leg portions so that the lengths of at least some of the legs can be

appropriately adjusted to compensate for any irregularities in the support surface or the ground on which the sawhorses are positioned.

Referring to Fig. 2, legs 22a, 22b are pivoted about pivots 24, the reference numeral 26 representing the initial clockwise pivoting of the legs from the collapsed conditions within the arms to the extended positions and, subsequently, the

counterclockwise movement to restore the legs to the collapsed conditions. Similarly, the reference number 28 represents the initial pivoting movements in a counterclockwise direction of the legs 22b from the retracted or collapsed conditions within the arm 12b, and subsequent movement in a clockwise direction for collapsing such legs.

In order to optimize the stability of the sawhorse at least one of the legs of each pair are preferably pivoted from the collapsed conditions within the arms 12a, 12b to positions forming angles a no greater than 90° with their associated arms as shown, angles a within the range of 75-90° providing optimal stability while maintaining the work surfaces at practical and convenient vertical levels or heights during use.

It will be noted from Fig. 2 that when the arms 12a, 12b are extended to be inline and arranged along a horizontal direction, the rectangular notches or recesses 20a, 20b are upwardly open as shown. The notches or recesses of preferably dimensioned to correspond to the cross-sectional dimensions of standard structural beams, such as 2x4s or 4x6s, that are readily available in lengths of 8 feet and longer and can be cut to a desired size to create a worktable or workstation suitable for a given application or project.

The telescoping actions are represented by the arrow 30 after the contracted legs are withdrawn from an associated arm.

Referring to a Figs. 3, 4 the procedure for creating a worktable or workstation is illustrated. After two sawhorses 10, 10' have been fully expanded they are spaced from each other with the upper, horizontal support arms in generally parallel relationship and with the rectangular notches or recesses 20a, 20b generally aligned with each other as shown in Fig. 3 to allow suitably sized support beams 32a, 32b to be placed within a notches or recesses as shown, after which a flat panel 34, such as a sheet of plywood, can be deposited on the support beams to complete the worktable or workstation. Selected legs can be adjusted in height, either before or after support beams and flat panel are in place to level the surface of the flat panel within a substantially horizontal plane. If desired, the flat panel 34 can be secured to the support beams 32a, 32b by means of fasteners, such as screws, or clamps or the like.

Referring to Figs. 5-16, a second embodiment 10" is illustrated that includes a single arm or support member 36 instead of the two articulated arms 12a, 12b used in the first embodiment 10. The single support member 36 is rigid and is likewise configured to receive two sets of leg assemblies 38L, 38R, these being the left and right leg assemblies as viewed in Fig. 5. Since the leg assemblies, and each end of the single support member 36 are similar in many respects, it will be appreciated that the description of the leg assembly at one end of the support member 36 is mostly applicable, with some minor variations, to the other leg assembly at the other end of the support member. As suggested in Figs. 6 and 7, the primary difference resides in that the right leg assembly 38R is collapsed first into the support member 36 so that it positioned further in or further up, as viewed in these Figures, closer to the top wall 36a, while the left leg assembly 38L is collapsed into the support member after the right leg assembly has been moved into the support member as shown and, therefore the two leg assemblies are vertically offset from each other. That offset accounts for and dictates the differences in the way that the two leg assemblies are mounted, but otherwise they are substantially the same.

Referring to Figs. 6, 7, the left leg assembly 38L includes a right angle or L- shaped bracket 40 comprising portions 40a, 40b arranged perpendicularly to each other as shown in Figs. 6, 7. The bracket 40 is pivotally secured proximate to the left end of the support member 36, as viewed in Fig. 7, by means of a pivot 42. The portion 40a shares the pivoting motions of the portion 40b as these are rigidly joined to each other.

A pivot 44 is arranged on the portion 40b for pivotally supporting legs 38a, 38b that are initially juxtaposed against each other when collapsed and that separate from each other about the pivot 44 so as to become angularly displaced from each other as suggested, for example, in Figs. 10-12. As will become evident, the legs 38a, 38b can only angularly separate from each other by pivoting about the pivot 44 after the bracket 48 has been displaced approximately 180° to the position shown in Fig. 1 1 and moved to clear and not interfere with the pivotal movements of the legs 38a, 38b.

The bracket 48 includes a portion 48a that is pivotally supported by means of the pivot 42. When in the expanded position, shown on the right side in Fig. 8, a U-shape cut out 46b is dimensioned to receive a support beam, such as a 2 x 4, as discussed in relation to the notches or recesses 20a, 20b. Bracket portions 48a, 48b are spaced from each other and on opposite sides of the bracket portion 40a, support a pin or pivot 62 that may form part of a fastener as shown. The pin or pivot 62 extends through the bracket and the portion 40a so that the bracket 48 can rotate about the pin or pivot 42 relative to the bracket 40 while the bracket 40 can rotate about fixed pivot pin 50 that also supports the leg chassis spacer 52, as shown in Fig. 7. The pin 62 engages the portion 40a to provide a cam-follower arrangement so that clockwise rotation of the bracket 48 causes the bracket 40 and the leg assembly 38L to follow. The cam-follower arrangement is designed to cause the leg assembly to rotate approximately 90° when the bracket 48 is rotated 180°. Since the bracket 48 and the leg assembly are coupled or linked for coordinated movements it is not critical whether the bracket 48 or the leg assembly is manually actuated since the other member will follow.

The bracket portion 48a has a cutout 48d, as shown, to allow the bracket 48 to pivot approximately 1 80° counter-clockwise as the bracket 40 pivots approximately 90° clockwise and stop further pivoting actions when the spacer 52 comes into abutment with the edge 48e once the bracket is in its fully extended position shown, for example, on the right side in Fig. 7.

A spring loaded locking button 54 is provided on the bracket portion 48a to lock the retracted legs when received within the hole or aperture 56 within the front panel 36f of the member 36.

The pivot 42 in cooperation with the earning action of the pin or pivot 62 engaging a slot or (not shown) in the bracket portion 40a cut out causes the bracket 48 to rotate in a clockwise direction as the leg assembly 38L is rotated in a clockwise direction CW, so that when the leg assembly 38L reaches its extended position, by pivoting approximately 90°, the bracket 48 rotates 180° to the position shown, for example, in Fig. 1 1. Similarly, in Fig 6 the leg assembly 38L is extended by pivoting action in a clockwise direction CW. While one cam arrangement for moving the brackets 46 by angular displacements substantially equal to twice the angular displacements of the leg assemblies with which they are associated, it will be evident that numerous other cam, gear and linkage arrangements can be used to achieve this effect.

As with the previous embodiment, the leg assemblies 38L, 38R preferably also include extendable leg portions, such as inner telescoping tubes 84 for selectively adjusting the lengths of the legs by means of openings 84a or any other suitable detent mechanisms well known to those skilled in the art. The inner telescoping tube 68 and outer telescoping tube 86 can be selectively locked by means of a locking tab 60, although any other locking arrangement can be used, with different degrees of advantage.

After the legs have been moved to their extended positions and the bracket 48 has been placed into its operative position, as shown in Fig. 1 1 , the legs 38a, 38b may be separated as suggested by arrow 88. Links 92a, 92b can be used to secure the legs in their intended or desired positions as shown in Fig. 1 1 , a handle contactor 92 be used to apply pressure on the links to bring them into linear alignment as shown in Fig. 1 1, preferably serving as a toggle beyond a dead of center or center point to maintain the links in the positions shown during use.

Provided on the brackets 48 are spring-loaded lock buttons 54 that are biased to extend outwardly in directions normal the brackets 48a. Openings 56 (Figs. 5, 1 1) are arranged to be aligned with the buttons 54 when the leg assemblies are fully retracted within support member 36, at which time the buttons 54 are urged through the openings 56 to lock the leg assemblies within the support member 36. The buttons 54, therefore, serves as a release button and when manually pushed inwardly to clear the openings 56, lock the leg assemblies and permit them to move to the extended or open operative positions.

Referring to Fig. 8, the leg assembly 38R is shown in an intermediate position. Instead of an L-shaped bracket 40 a straight rectangular tube 74 at the lower end of which the pivot 44 supports the leg assembly 38R that allows the legs 38a, 38b to collapse as shown and to open, spread or separate as shown in Figs. 10 and 1 1. The other end of the tube 74 is pivotally mounted about leg chassis pivot 80 that is fixed on the support member 36.

The tube 74 has a guide slot 74' that serves as a cam guide for the pin or cam 78 that moves within the slot to pivot the bracket 70. The cam elements are arranged to move the leg assembly 38R approximately 90° as the bracket 70 is manually pivoted 180° from the retracted position shown in Figs. 6,7 to the extended position shown in Figs. 5, 9, 10, 1 1. Therefore, after the release buttons 54 are pushed this allows the brackets 48, 70 to be manually moved to the extended or operative positions, moving with them the leg assemblies to their operative positions.

As demonstrated in Figs. 12-14, once the sawhorses 10, 10' have been fully expanded they may be used to create a work table or workstation in the same way as described in connection with Figs. 3,4.

A feature of the sawhorses of the present invention is the provision of support tabs or members 82 that are pivotally mounted proximate the lower ends of the legs 38a, as shown in Fig. 15, about pivot 82a. The support tabs or members 82 can be formed from stamped material or molded plastic and formed with edges 82b and 82c, these edges being arranged so that the edge 82c are suitable for supporting a workpiece when the support tab 82 has been pivoted to bring the edge 82b into contact with the leg 38a. The specific configuration of the support tabs 82 are not critical and differently configured support members can be used to support a workpiece may be used. Referring to Fig. 16 a sawhorse is shown with the support tabs 82 on both legs pivoted to the support positions so that a workpiece, such as a sheet of plywood or sheetrock panel can be placed on the support tabs for purposes of measurement, cutting or the like while protecting the panel from conditions on the ground.

A further embodiment is illustrated in Figs. 17-20 that differs from the earlier described embodiments in that the lateral or the side brackets for receiving the elongate members 32 are not coupled or linked to the leg assemblies but each can be

independently extended or retracted in relation to the support member 36. Thus, referring primarily to Fig. 18 each bracket 48' includes a vertical gripping portion 48v and a sliding horizontal portion 48h. The horizontal portion 48h has a central horizontal slot 100 that extends substantially the entire length of the horizontal portion 48h. The vertical portion 48v defines a vertical edge 48e that faces or opposes the fixed cap 46 to effectively create an adjustable rectangular receiving space there between that can receive a support member 32, such as a 2 x 4. Fixed on the support member 36 are a pair of spaced pins 102a and 102b that are spaced from each other along a horizontal direction. The pins 102a and 102b have an enlarged head and/or are provided with a washer or the like so that the pins extend through and are captured within the slot 100 and the bracket 48' becomes locked into the support member 36 against all movements except for lateral sliding movements permitted by movements of the pins within the slot.

Since the bracket 48' is U-shaped (see Figs. 19 and 20) the slotted portions 48h that engage the support member contact the front and rear sides thereof. The bracket 48', therefore, does not extend into the support member 36 but bridges or extends about the same and does not interfere with the movements of the leg assemblies. In Fig. 18, the leg assembly is pivotably attached by a support member 104 and a pivot pin 106 so that the leg assembly can be extended by pivoting 90° to the position shown and, subsequently, can be retracted into the support member 36.

For reasons discussed, it is important for the leg assemblies to be vertically offset in relation to the horizontal support member when fully retracted so that each leg assembly can be received within the support member without interfering with the other retracted leg assembly. Referring to Fig. 17, therefore, it will be noted that the leg support pivot pins 106 are vertically offset or positioned at different heights 108, 1 10 at the opposite lateral ends of the support member. Since the leg assemblies are otherwise similar to the ones previously described the details thereof will not be repeated as the previous discussion of the leg assemblies is equally applicable to this additional embodiment.

In use, the embodiment of Figs. 17-20 allows either one or both of the lateral or side brackets to be independently extended as may be required or desired in any given application.

Thus, the sawhorses in accordance with the present invention are simple and practical and can be used by both professionals and DYI people alike to quickly and conveniently create suitably dimensioned and stable work tables or workstations, as well as for measuring and cutting workpieces as described. Importantly, the sawhorses are extremely compact and, when collapsed, can be easily transported and stored. Extending or collapsing the sawhorses is extremely simple and convenient and can be performed very rapidly with no special experience or tools required.

The foregoing is considered as illustrative only of the principles of the invention. Further, since numerous modifications and changes won't readily occur to those skilled in the art, it is not designed to limit the invention to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.