BACKGROUND OF THE INVENTION

1. Field of Invention The invention of the present application relates to woodworking and in particularly to an apparatus for coping a workpiece by tracing a corresponding face profile of a similar workpiece.

2. Description of Related Art Coping or scribing as it may also be referred to as, is the technique of shaping the end of a moulding or frame component to fit the contours of an abutting moulding or frame component. Coping is preferred to mitering as it allows for clean joints between intersecting members when walls are not square to each other and the effect of shrinkage is minimized among other reasons. Coping is commonly used in cabinet making for mouldings and frame components.

The technique may also be used in the construction of doors and windows.

Traditionally, coping would be performed using a coping saw. However, considerable skill is required in forming accurately coped ends even with relatively simple moulding shapes. Additionally, instances in which the moulding pieces meet at a corner which is not exactly ninety degrees further increases the difficulty of properly forming an accurate coped end. Coping is typically done by scribing the joint with an internal mitre cut. The cut is then coped by cutting along the inside face of the mitre cut at a right angle to the board. These methods of coping require a great deal of skill and are time consuming.

SUMMARY OF THE INVENTION

A coping apparatus comprising a first support for supporting a first workpiece and a second support for supporting a second workpiece. The first workpiece has a first face profile and extends along a first longitudinal axis. The second workpiece has a second face profile and extends along a second longitudinal axis. The coping apparatus further comprises a tracing assembly disposed to one side of the first workpiece. The tracing assembly has a follower and a cutter. The follower is adapted to follow the second face profile in a direction substantially perpendicular to the second axis so as to move the cutter along a path corresponding to the second face profile. The cutter extends across the first workpiece so as to cut an end profile into the first workpiece corresponding to the second face profile.

The first and second axes may be orthogonal to each other. The first and second axes may be coplanar.

The tracing assembly may further comprise a tracing carriage supporting the follower and the cutter. The tracing carriage may be moveable in first and second orthogonal directions. The first direction may be parallel to the first longitudinal axis of the first workpiece and the second direction may be orthogonal to the first and second longitudinal axes.

The tracing carriage may be supported by first and second perpendicular tracks. The first and second tracks may permit the tracing carriage to be rotatably fixed and slidable relative thereto. The first and second tracks may each comprise first and second spaced apart rods.

Each of the first spaced apart rods may slidably support an end carriage. The end carriages may support the second spaced apart rods therebetween wherein the second spaced apart rods may slidably support the tracing carriage. The end carriages may further include linear bearings for slidably supporting the end carriages on the first spaced apart rods. The tracing carriage may further include linear bearings for slidably supporting the tracing carriage on the second spaced apart rods.

The cutter may extend from the tracing carriage about a cutter axis. The cutter axis may be seiectably orientable relative to the tracing carriage so as to permit the cutter to intersect the first workpiece at one of a plurality of cut angles. The cut angle may be selected from between 45 and 135 degrees from the longitudinal axis of the first workpiece. The cutter may be pivotally secured to the tracing carriage.

The cutter may comprise a rotary cutting tool. The rotary cutter may have an axis substantially perpendicular to a longitudinal axis of the first workpiece.

The first and second face profiles may be substantially similar.

BRIEF DESCRIPTION OF THE DRAWINGS

In drawings which illustrate embodiments of the invention wherein similar characters of reference denote corresponding parts in each view,

Figure 1 is a perspective view of an apparatus for coping a workpiece according to a first embodiment of the present invention. Figure 2 is a detailed front perspective view of the tracing assembly of the apparatus of Figure 1. Figure 3 is a detailed rear perspective view of the tracing assembly of the apparatus of Figure 1.

Figure 4 is an exploded view of the tracing assembly of Figure 2. Figure 5 is a front elevation view of the apparatus of Figure 1 coping the face profile of a first workpiece into the end of a second workpiece.

Figure 6 is a top plan view of the apparatus of Figure 1 coping the face profile of a first workpiece into the end of a second workpiece at a perpendicular angle.

Figure 7 is a top plan view of the apparatus of Figure 1 coping the face profile of a first workpiece into the end of a second workpiece at a non-perpendicular angle. Figure 8 is a front elevation view of first workpiece coped by the apparatus of Figure 1 for joining with the second workpiece.

Figure 9 is a perspective view of an apparatus for coping a workpiece according to an alternative embodiment of the present invention having clamps for securing the first and second workpieces thereto. DETAILED DESCRIPTION

Referring to Figure 1 , an apparatus for coping a first workpiece 8 is illustrated generally at 10. The coping apparatus 10 comprises a support base 12 supporting a profile support or platform 20, a coping support or platform 30 and a tracing assembly 40. The coping support 30 is adapted to receive and secure a first workpiece 8 thereto wherein the first workpiece is to be coped or otherwise cut as discussed further below. The profile support 20 is adapted to receive and hold a second workpiece 6 having a face profile 5 thereon. The tracing assembly 40 is adapted to trace the face profile 5 of the second workpiece 6 so as to cut an end profile 9 into the end of the first workpiece 8 wherein the end profile 9 corresponds to the face profile 5 of the second workpiece 6. It will be appreciated that an end profile 9 of the first workpiece 8 so coped may abut against and closely follow the face profile 5 of the second workpiece 6. It will further be appreciated, that in many instances the first and second workpieces 8 and 6 will be selected to have corresponding profiles for fitting the first and second workpieces to a corner joint.

The profile support 20 comprises a substantially horizontal support surface 22 and a substantially vertical adjoining back surface 24. The profile support is adapted to receive a second workpiece on a support surface 22 thereof. The profile support 20 may aiso include a profile clamp 110 or other suitable means for clamping or otherwise securing the second workpiece against the back surface 24 of the profile support 20 as illustrated in Figure 9. The profile clamps 110 may comprise a profile clamp surface 112 supported by an upright profile damp arm 114. A threaded knob or handle 116 may be utilized to pull or otherwise urge the upright profile clamp arm towards the second workpiece so as to bear the profile clamp surface 112 against the face profile 5 of the second workpiece so as to securely retain the second workpiece on the profile support 20. It will be appreciated that other types of damps as are commonly known may also be useful as well such as, by way of non-limiting example, c-claims or by means of securing the second workpiece to the profile support with a screw or other fastener. The coping support 30 comprises a substantially horizontal support surface 32 and a substantially vertical adjoining back surface 34. The coping support 30 is adapted to receive a first workpiece on a support surface 22 thereof. The coping support 30 may aiso include a coping clamp 100 or other suitable means for clamping or otherwise securing the first workpiece 8 against the back surface 34 of the coping support 30 as illustrated in Figure 9. The coping clamps 100 may comprise a coping clamp surface 102 supported by an upright coping clamp arm 104. A threaded knob 106 or handle 108 may be utilized to pull or otherwise urge the upright coping clamp arm towards the first workpiece so as to bear the coping clamp surface 102 against the face profile 5 of the second workpiece so as to securely retain the second workpiece on the coping support 30. It will be appreciated that other types of clamps as are commonly known may also be useful as well such as, by way of non-limiting example, c-clamps or by means of securing the second workpiece to the profile support with a screw or other fastener.

As illustrated in Figure 1 , the first workpiece 8 has a first longitudinal axis 7 and the second workpiece 6 has a second longitudinal axis 4. As illustrated the first and second workpieces 8 and 6 may be secured to the profile and coping supports 20 and 30 such that the first and second longitudinal axes 7 and 4 intersect each other. In such an arrangement, the first and second longitudinal axes 7 and 4 will be co-planar. It will also be appreciated that other orientations of the first and second workpieces may also be utilized wherein the first and second longitudinal axes 7 and 4 do not intersect wherein the first and second workpieces 7 and 4, respectively will still be substantially perpendicular to each other.

Turning now to Figures 2 and 3, the tracing assembly comprises first and second tracks 42 and 44 cooperating to support a tracing carriage 46. As illustrated the first and second tracks 42 and 44 are perpendicular to each other although other relative orientations may be useful as well. The tracing carriage 46 includes a follower 48 and a cutter 50 extending therefrom. In operation, the tracing carriage 46 is moveable in first or horizontal and second or vertical directions as indicated generally at 52 and 54, respectively. In operation, the tracing carriage 46 may be moved in such a manner that the follower 48 follows the profile of the first workpiece as the tracing carriage is moved in a vertical direction 52 while the follower 48 moves the tracing carriage in a horizontal direction 54 corresponding to the face profile 5 of the second workpiece 6 at that height. As the tracing carriage 46 is moved in the first and second directions 52 and 54 corresponding to the profile of the first workpiece, the cutter 50 cuts a corresponding end profile 9 into the first workpiece 8.

As illustrated, the first track 42 comprises first and second parallel spaced apart rods 58 and 60. The first and second rods 58 and 60 are secured at their bottom ends 62 and 64, respectively while the top ends of the first and second rods may be secured to each other by a bridging member 66. The first and second rods 58 and 60 slidably locate first and second end carriages

68 and 70, respectively, thereon. The first and second end carriages 68 and 70 may include vertical linear bearings 71 (as shown in Figure 4) or bushings therein for enabling the end carriages to slidably move on the rods in an axial direction. The second track 44 comprises third and fourth parallel spaced apart rods 72 and 74. The third and fourth rods 72 and 74 extend between and are secured at each end to the first and second end carriages 68 and 70. The tracing carriage 46 may include horizontal linear bearings 75 (as shown in Figure 4) or bushings therein for enabling the tracing carriage to slidably move on the third and fourth rods in an axial direction. As illustrated, the third and fourth rods may be spaced apart from each other on a horizontal plane which is orthogonal to a vertical plane on which the first and second rods are spaced apart from each other, it will be appreciated however, that the third and fourth rods may also be spaced apart from each other on a vertical plane which is parallel to a vertical plane on which the first and second rods are spaced apart from each other.

Turning to Figure 4, an exploded view of the tracing assembly 40 is iiiustrated. The tracing carriage 46 comprises a tracing carriage body 47 slidably located on the second tracks 44 having a follower 48 and a cutter 50 extending therefrom. The follower 48 extend from the tracing carriage body 47 in a direction substantially parallel to the third and fourth rods 72 and 74. The followers have an end tracing surface 49 adapted to engage with closely follow the face profile 5 of a second workpiece 6. In some embodiments, the end tracing surfaces 49 may comprise a half rounded end to the follower 48. In other embodiments, the end tracing surface may comprise a ball bearing tip. As illustrated in Figure 1, the follower 48 is oriented to extend from the tracing assembly 40 at an angle substantially perpendicular to the back surface 24 of the profile support. Accordingly the follower 48 will engage the face profile 5 of the second workpiece at a substantially normal angle.

The cutter 50 extends from a rearmost portion 76 of the tracing carriage body 47. The cutter 50 extends from a drive motor 78 or other suitable actuation means. In the embodiment illustrated, the cutter 50 may be a rotary type cutter while the drive motor 78 comprises an electric motor. It will be appreciated that the cutter 50 and drive motor 78 may be adapted from conventional rotary tools as are known in the art. It will be appreciated that the cutter 50 may also comprise a longitudinally moving cutter such as a reciprocating saw, by way of non-limiting example. The drive motor 78 is secured to a pivot bar 80 by any suitable means. The pivot bar comprises an elongated member having a top pivot pin 82 extending therefrom. The pivot pin 82 is rotatably received within a bore 84 on the tracing carriage body 47 and rotatably secured therein with a cap 86 or other suitable fastening means.

The tracing carriage body 47 also includes a curved front face 90 having a radius centered within the bore 84. The front face includes a plurality of indentation 92 adapted to cooperate with the pivot bar 80 to orient the cutter 50 at a plurality of selectable orientations relative to the first workpiece 8. The pivot bar 80 further includes an upturned portion 94 having a threaded bore

(not shown) therein. The threaded bore receives a thumbwheel 96 or other suitable means. The thumbwheel 96 aligns with the indentations 92 so as to be selectively engagable with a desired indentation to retain the pivot bar 80 and cutter 50 at a desired angle relative to the first workpiece 8. By way of non-limiting example, indentations 92 may be provided for orienting the cutter 50 normal to the first workpiece 8 as illustrated in Figure 6 or at angles of 15, 3O ₁ and 45 degrees from normal as illustrated in Figure 7 although it will be appreciated that other angles may also be useful. The tracing carriage body

47 may also include a handle 98. As illustrated in Figures 6 and 7, the entire tracing assembly 40 with the exception of the cutter 50 is located in such a position that it will be located entirely to the face side of the first workpiece. In this way the tracing assembly 40 will not interfere with a first workpiece 8 located on the apparatus. This will enable the apparatus of the present invention to perform a coped cut at an intermediate location in such a workpiece and not require the workpiece first be cut to length.

In operation, a first workpiece 8 which is to be coped may be secured to the coping support 30 at a location such that the cutter will engage the first workpiece 8 at the appropriate distance aiong it's length. A second workpiece 6 have a face profile 5 that is to be traced may be secured to the first profile. The user may then bring the follower 48 corresponding to the face profile 5 into contact therewith. After starting the cutter 50, the user may then move the tracing carriage 46 in a generally downward movement while keeping the tracing surface 49 of the follower 48 in contact with the face profile. During this movement the cutter 50 will cut an end profile 9 into the first workpiece corresponding to the face profile 5. Thereafter the first and second workpieces 8 and 6 may be removed for installation wherein the end profile 9 will closely engage the face profile 5 as illustrated in Figure 8. It will be appreciated that in order to make a downward cut, the user should first locate the cutter 50 and follower 48 above the first and second workpieces 8 and 6 while in order to make an upward cut, the user may keep the cutter 50 and follower 48 below the first and second workpieces 8 and 6 while installing the workpieces.

It will be appreciated that although, the apparatus illustrated includes the first track 42 permitting movement in a vertical direction, and a second track 44 in a horizontal direction, that other orientations may also be possible. By way of non-limiting example, the first track may permit vertical movement through the use of horizontal rods to support horizontally moveabie end carriages. In such an embodiment, the second track may comprise vertically oriented rods between the end carriages supporting the tracing carriage through vertical movement.

It will also be appreciated that the first and second tracks may also comprise other track types. By way of non-limiting embodiment, the first and second tracks may each comprise one or more rectangular members wherein the tracing and end carriages include linear bearings for permitting single degree of freedom movement in an axial direction along the member. Types of member may include rectangular or c-shaped.

The apparatus may have two sets of supports as illustrated in Figure 1 to cut both a right and a left handed cope. In other embodiments, only the supports for cutting a singled handed cope may be included. As illustrated in Figure 1 , the apparatus is being utilized to cut a left handed cope. As illustrated it includes a left side profile support 20 and a right sided coping support 30. It will be appreciated, that in alternate embodiments, the apparatus 10 may include a right sided profile support 20 and a left sided coping support 30 for cutting right sided copes. Therefore the profile support 20 and the coping support 30 to be utilized will be on opposite sides of the tracing assembly 40.

It will aiso be appreciated that the present embodiment utilizes a selectively rotatable cutter extending from the tracing assembly to produce coped joints wherein the first and second workpieces are adapted to be connected at other than a 90 degrees angle. However it will be appreciated, that such coped joints may also be formed by rotating the coping support 30 relative to the profile support.

While specific embodiments of the invention have been described and illustrated, such embodiments should be considered illustrative of the inveπtioπ only and not as limiting the invention as construed in accordance with the accompanying claims.