Note: Descriptions are shown in the official language in which they were submitted.
CA 02885473 2015-03-19
SAW BLADE
This is a divisional application of Canadian Patent Application Serial No.
2,797,111 (filed on April 22, 2011).
BACKGROUND
[0001] The present invention relates to saw blades and, more particularly,
to saw blades
for use with power tools.
It should be understood that the expression "the invention" and the like used
herein may refer to subject matter claimed in either the parent or the
divisional applications.
[0002] Saw blades, such as reciprocating saw blades, are used for cutting
wood, metal,
plastics, and other materials.
[0003] A saw blade typically includes a body, one or more attachment
portions, and a
cutting portion. The cutting portion comprises a plurality of teeth made up of
one or more
tooth forms. Tooth forms on saw blades are a major factor in the durability,
cost, speed of
cutting, and accuracy and quality of cuts made. Each tooth typically includes
a tip, a relief
face, a rake face, and a gullet. The teeth are generally separated by a pitch
length
(otherwise identified as the number of teeth per inch (TPI)). Some tooth forms
vary along
the length of the saw blade or include portions having varied teeth. In some
tooth forms, a
nail may become lodged in the gullet of a tooth during operation, thereby
breaking or
otherwise damaging the tooth.
[0004] In many instances, the operator of a reciprocating saw uses the saw
and attached
saw blade to initiate and make cuts in construction material starting at an
edge, or
periphery, of the construction material. During such cuts, the cutting portion
and the
plurality of teeth associated therewith are the first part of the saw blade to
contact the
material. In other instances, the operator of the reciprocating saw uses the
saw and attached
saw blade to initiate a cut in a face of the construction material (i.e., away
from the edge, or
periphery, of the construction material). This type of cut is typically
referred to as a plunge
cut. During a plunge cut, a leading tooth located proximate the end of the saw
blade
penetrates the material face first. Therefore, the end geometry and the
leading tooth
geometry of the saw blade are significant to performance during plunge cutting
and may
1
CA 02885473 2015-03-19
affect the durability of the saw blade, the speed with which the plunge cut is
executed, and
the accuracy of the cut.
SUMMARY
[0005] In one embodiment, the invention provides a reciprocating saw blade
for use
with a reciprocating saw. The reciprocating saw blade includes a body having a
first end
portion and a
la
CA 02885473 2015-03-19
second end portion. The body defines a longitudinal axis. The reciprocating
saw blade also
includes an attachment portion coupled to the first end portion of the body.
The attachment
portion includes a tang and an aperture configured to couple to the
reciprocating saw. The
reciprocating saw blade further includes a cutting portion formed on the body.
The cutting
portion includes a plurality of cutting teeth. Each cutting tooth includes a
tip, a rake face
extending from the tip generally toward the longitudinal axis and defining a
gullet, and a relief
surface extending from the tip generally toward the second end portion of the
body. The
reciprocating saw blade also includes a plunge point formed on the second end
portion of the
body for initiating a plunge cut. The plunge point includes a leading tooth
and a second tooth.
The leading tooth includes a tip and a rake face extending from the tip
generally toward the
longitudinal axis and defining a leading gullet that extends from the rake
face of the leading
tooth to the plurality of cutting teeth. The second tooth is positioned in the
leading gullet closer
to the leading tooth than to a nearest cutting tooth of the plurality of
cutting teeth and the second
tooth being generally smaller than the leading tooth and each of the plurality
of cutting teeth.
The plurality of cutting teeth is arranged in a series from the first end
portion of the body to the
leading gullet without any intervening teeth therebetween. The tips of the
plurality of cutting
teeth and the tip of the leading tooth define a plane that is generally
parallel to the longitudinal
axis and a tip of the second tooth is spaced apart from the plane.
[0006] In
another embodiment, the invention provides a reciprocating saw blade for use
with
a reciprocating saw. The reciprocating saw blade including a body having a
first end portion and
a second end portion. The body defines a longitudinal axis. The reciprocating
saw blade also
includes an attachment portion coupled to the first end portion of the body.
The attachment
portion includes a tang and an aperture configured to couple to the
reciprocating saw. The
reciprocating saw blade further includes a cutting portion formed on the body.
The cutting
portion includes a plurality of cutting teeth. Each cutting tooth includes a
tip, a rake face
extending from the tip generally toward the longitudinal axis and defining a
gullet, and a relief
surface extending from the tip generally toward the second end portion of the
body. The
reciprocating saw blade also includes a plunge point formed on the second end
portion of the
body for initiating a plunge cut. The plunge point includes a leading tooth
having a tip and a
rake face extending from the tip generally toward the longitudinal axis and
defining a leading
gullet. The tips of the plurality of cutting teeth and the tip of the leading
tooth define a plane that
2
CA 02885473 2015-03-19
is generally parallel to the longitudinal axis. A first angle between the
plane and the rake face of
the leading tooth, measured through the leading tooth, is greater than 90
degrees, and a second
angle between the plane and the rake face of each cutting tooth, measured
through the
corresponding cutting tooth, is less than 90 degrees.
[0007] In yet another embodiment, the invention provides a reciprocating
saw blade for use
with a reciprocating saw. The reciprocating saw blade includes a body having a
first end portion
and a second end portion. The body defines a longitudinal axis. The
reciprocating saw blade
also includes an attachment portion coupled to the first end portion of the
body. The attachment
portion includes a tang and an aperture configured to couple to the
reciprocating saw. The
reciprocating saw blade further includes a cutting portion formed on the body.
The cutting
portion includes a plurality of cutting teeth. Each cutting tooth includes a
tip, a rake face
extending from the tip generally toward the longitudinal axis and defining a
gullet, and a relief
surface extending from the tip generally toward the second end portion of the
body. The
reciprocating saw blade also includes a plunge point formed on the second end
portion of the
body for initiating a plunge cut. The plunge point includes a leading tooth
and a second tooth.
The leading tooth includes a tip and a rake face extending from the tip
generally toward the
longitudinal axis and defining a leading gullet that extends from the rake
face of the leading
tooth to the plurality of cutting teeth. The leading gullet is at least twice
as large as each gullet
of the plurality of cutting teeth. The second tooth is positioned in the
leading gullet closer to the
leading tooth than to a nearest cutting tooth of the plurality of cutting
teeth and the second tooth
is generally smaller than the leading tooth and each of the plurality of
cutting teeth. The tips of
the plurality of cutting teeth and the tip of the leading tooth define a plane
that is generally
parallel to the longitudinal axis. A first angle between the plane and the
rake face of the leading
tooth, measured through the leading tooth, is greater than 90 degrees, and a
second angle
between the plane and the rake face of each cutting tooth, measured through
the corresponding
cutting tooth, is less than 90 degrees. The plurality of cutting teeth is
arranged in a series from
the first end portion of the body to the leading gullet without any
intervening teeth therebetween.
A tip of the second tooth is spaced apart from the plane.
3
CA 02 885473 2 015-03-1 9
WO 2011/133864 PCT/US2011/033583
[0008] In another embodiment, the invention provides a reciprocating saw
blade for use with
a reciprocating saw. The reciprocating saw blade is configured to cut a work
piece having a nail
extending therethrough. The reciprocating saw blade includes a body defining a
longitudinal
axis and an attachment portion coupled to the body. The attachment portion
includes a tang and
an aperture configured to couple to the reciprocating saw. The reciprocating
saw blade also
includes a cutting portion formed on the body. The cutting portion includes a
plurality of cutting
teeth. Each cutting tooth includes a tip, a rake face extending from the tip
generally toward the
longitudinal axis and at least partially defining a gullet, a relief surface
extending from the tip
and having a first end that is closer to the attachment portion and a second
end that is further
from the attachment portion, and a protrusion extending from the second end of
the relief
surface. The protrusion of each cutting tooth inhibits the nail from entering
the gullet and
contacting the rake face of an adjacent cutting tooth during cutting
operations.
[0009] In yet another embodiment, the invention provides a reciprocating
saw blade for use
with a reciprocating saw. The reciprocating saw blade includes a body defining
a longitudinal
axis and an attachment portion coupled to the body. The attachment portion
includes a tang and
an aperture configured to couple to the reciprocating saw. The reciprocating
saw blade also
includes a cutting portion formed on the body. The cutting portion includes a
plurality of cutting
teeth. Each cutting tooth includes a tip, a relief surface extending from the
tip, and a protrusion
extending from an end of the relief surface opposite the tip. The tips of the
plurality of cutting
teeth define a first plane that is generally parallel to the longitudinal axis
and the protrusions of
the plurality of cutting teeth define a second plane that is generally
parallel to the longitudinal
axis. A distance between the first plane and the second plane is at most
approximately 0.035
inches.
[0010] In still another embodiment, the invention provides a reciprocating
saw blade for use
with a reciprocating saw. The reciprocating saw blade includes a body defining
a longitudinal
axis and an attachment portion coupled to the body. The attachment portion
includes a tang and
an aperture configured to couple to the reciprocating saw. The reciprocating
saw blade also
includes a cutting portion formed on the body. The cutting portion includes a
plurality of cutting
teeth. Each cutting tooth includes a tip, a relief surface extending from the
tip, and a protrusion
extending from an end of the relief surface opposite the tip. Each cutting
tooth defines an
4
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
effective relief surface that extends from the tip and is tangent to the
protrusion. A distance
between effective relief surfaces of adjacent cutting teeth is at most
approximately 0.06 inches.
[0011] In another embodiment, the invention provides a reciprocating saw
blade for use with
a reciprocating saw. The reciprocating saw blade includes a body defining a
longitudinal axis
and an attachment portion coupled to the body. The attachment portion includes
a tang and an
aperture configured to couple to the reciprocating saw. The attachment portion
is angled relative
to the longitudinal axis by a tang angle. The reciprocating saw blade also
includes a cutting
portion formed on the body. The cutting portion includes a plurality of
cutting teeth. Each
cutting tooth includes a tip, a relief surface extending from the tip, and a
protrusion extending
from an end of the relief surface opposite the tip. Each cutting tooth defines
an effective relief
surface that extends from the tip and is tangent to the protrusion. The tips
of the plurality of
cutting teeth define a plane that is generally parallel to the longitudinal
axis. The relief surface
of each cutting tooth intersects the plane at a relief angle and the effective
relief surface of each
cutting tooth intersects the plane at an effective relief angle. The effective
relief angle is
between the tang angle and the relief angle.
[0012] In yet another embodiment, the invention provides a reciprocating
saw blade for use
with a reciprocating saw. The reciprocating saw blade is configured to cut a
work piece having a
nail extending therethrough. The reciprocating saw blade includes a body
defining a longitudinal
axis and an attachment portion coupled to the body. The attachment portion
includes a tang and
an aperture configured to couple to the reciprocating saw. The attachment
portion is angled
relative to the longitudinal axis by a tang angle. The reciprocating saw blade
also includes a
cutting portion formed on the body. The cutting portion includes a plurality
of cutting teeth.
Each cutting tooth includes a tip, a rake face extending from the tip
generally toward the
longitudinal axis and at least partially defining a gullet, a relief surface
extending from the tip,
and a protrusion extending from an end of the relief surface opposite the tip.
The protrusion of
each cutting tooth inhibits the nail from entering the gullet and contacting
the rake face of an
adjacent cutting tooth during cutting operations. Each cutting tooth defines
an effective relief
surface that extends from the tip and is tangent to the protrusion. The tips
of the plurality of
cutting teeth define a first plane that is generally parallel to the
longitudinal axis and the
protrusions of the plurality of cutting teeth define a second plane that is
generally parallel to the
CA 02885473 2015-03-19
longitudinal axis. A distance between the first plane and the second plane is
at most
approximately 0.035 inches. A distance between effective relief surfaces of
adjacent
cutting teeth is at most approximately 0.06 inches. The relief surface of each
cutting tooth
intersects the first plane at a relief angle and the effective relief surface
of each cutting
tooth intersects the first plane at an effective relief angle. The effective
relief angle is
between the tang angle and the relief angle.
Aspects of the present invention are provided by the following clauses.
CLAUSES
1. A reciprocating saw blade for use with a reciprocating saw, the
reciprocating saw
blade comprising:
a body having a first end portion and a second end portion, the body defining
a
longitudinal axis;
an attachment portion coupled to the first end portion of the body, the
attachment
portion including a tang and an aperture configured to couple to the
reciprocating saw;
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a rake face extending from
the tip generally
toward the longitudinal axis and defining a gullet, and a relief surface
extending from the
tip generally toward the second end portion of the body; and
a plunge point formed on the second end portion of the body for initiating a
plunge
cut, the plunge point including a leading tooth and a second tooth, the
leading tooth
including a tip and a rake face extending from the tip generally toward the
longitudinal axis
and defining a leading gullet, the second tooth being positioned in the
leading gullet
adjacent the leading tooth and being generally smaller than the leading tooth
and each of
the plurality of cutting teeth.
2. The reciprocating saw blade of clause 1, wherein the tips of the
plurality of cutting
teeth and the tip of the leading tooth define a plane that is generally
parallel to the
longitudinal axis, and wherein the second tooth is spaced apart from the
plane.
6
CA 02885473 2015-03-19
3. The reciprocating saw blade of clause 1, wherein each cutting tooth has
a first
utmost width measured generally parallel to the longitudinal axis, the leading
tooth has a
second utmost width measured generally parallel to the longitudinal axis, and
the second
tooth has a third utmost width measured generally parallel to the longitudinal
axis, and
wherein the third utmost width is less than the first utmost width and the
second utmost
width.
4. The reciprocating saw blade of clause 1, wherein the leading gullet is
larger than
each gullet of the plurality of cutting teeth.
5. The reciprocating saw blade of clause 4, wherein the leading gullet is
at least twice
as large as each gullet of the plurality of cutting teeth.
6. The reciprocating saw blade of clause 5, wherein the leading gullet is
approximately
four times larger than each gullet of the plurality of cutting teeth.
7. The reciprocating saw blade of clause 1, wherein a ratio between a
distance from the
tip of the leading tooth to the tip of the nearest cutting tooth, measured
generally parallel to
the longitudinal axis, and a distance between the tips of adjacent cutting
teeth, measured
generally parallel to the longitudinal axis, is approximately 2Ø
8. The reciprocating saw blade of clause 1, wherein the second tooth
includes a tip,
and wherein a ratio between a distance from the tip of the leading tooth to
the tip of the
nearest cutting tooth, measured generally parallel to the longitudinal axis,
and a distance
from the tip of the leading tooth to the tip of the second tooth, measured
generally parallel
to the longitudinal axis, is approximately 6.6.
9. The reciprocating saw blade of clause 1, wherein the second tooth
includes a tip,
and wherein a ratio between a distance from the tip of the leading tooth to
the tip of the
second tooth, measured generally parallel to the longitudinal axis, and a
distance between
the tips of adjacent cutting teeth, measured generally parallel to the
longitudinal axis, is
approximately 0.3.
10. The reciprocating saw blade of clause 1, wherein the second tooth is
generally V-
shaped.
6a
CA 02885473 2015-03-19
11. The reciprocating saw blade of clause 1, wherein the second tooth
includes a tip, a
rake face extending generally toward the longitudinal axis, and a relief
surface extending
generally toward the leading tooth, wherein the tips of the plurality of
cutting teeth define a
plane that is generally parallel to the longitudinal axis, and wherein a first
angle between
the plane and the rake face of the second tooth, measured through the second
tooth, is
greater than 90 degrees.
12. The reciprocating saw blade of clause 11, wherein the first angle is
approximately
95 to 105 degrees.
13. The reciprocating saw blade of clause 11, wherein a second angle
between the plane
and the rake face of each cutting tooth, measured through the corresponding
cutting tooth,
is less than 90 degrees.
14. The reciprocating saw of clause 11, wherein a third angle between the
plane and the
rake face of the leading tooth, measured through the leading tooth, is greater
than 90
degrees.
15. A reciprocating saw blade for use with a reciprocating saw, the
reciprocating saw
blade comprising:
a body having a first end portion and a second end portion, the body defining
a
longitudinal axis;
an attachment portion coupled to the first end portion of the body, the
attachment
portion including a tang and an aperture configured to couple to the
reciprocating saw;
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a rake face extending from
the tip generally
toward the longitudinal axis and defining a gullet, and a relief surface
extending from the
tip generally toward the second end portion of the body; and
a plunge point formed on the second end portion of the body for initiating a
plunge
cut, the plunge point including a leading tooth having a tip and a rake face
extending from
the tip generally toward the longitudinal axis and defining a leading gullet;
wherein the tips of the plurality of cutting teeth and the tip of the leading
tooth
define a plane that is generally parallel to the longitudinal axis, wherein a
first angle
between the plane and the rake face of the leading tooth, measured through the
leading
tooth, is greater than 90 degrees, and wherein a second angle between the
plane and the
6b
CA 02885473 2015-03-19
rake face of each cutting tooth, measured through the corresponding cutting
tooth, is less
than 90 degrees.
16. The reciprocating saw blade of clause 15, wherein the first angle is
approximately
95 to 105 degrees.
17. The reciprocating saw blade of clause 15, wherein the second angle is
approximately 80 to 88 degrees.
18. The reciprocating saw blade of clause 15, wherein each cutting tooth
has a first
utmost width measured generally parallel to the longitudinal axis and the
leading tooth has
a second utmost width measured generally parallel to the longitudinal axis,
and wherein the
second utmost width is less than the first utmost width.
19. The reciprocating saw blade of clause 15, wherein the leading tooth
includes a relief
surface extending from the tip of the leading tooth to an end of the body, and
wherein a
third angle between the plane and the relief surface of the leading tooth is
greater than 45
degrees and less than 90 degrees.
20. The reciprocating saw blade of clause 19, wherein the third angle is
approximately
55 to 65 degrees.
21. The reciprocating saw blade of clause 19, wherein the end of the body
is generally
rounded.
22. The reciprocating saw blade of clause 15, wherein the leading gullet is
larger than
each gullet of the plurality of cutting teeth.
23. The reciprocating saw blade of clause 22, wherein the leading gullet is
at least twice
as large as each gullet of the plurality of cutting teeth.
24. The reciprocating saw blade of clause 23, wherein the leading gullet is
approximately four times larger than each gullet of the plurality of cutting
teeth.
25. The reciprocating saw blade of clause 15, wherein a ratio between a
distance from
the tip of the leading tooth to the tip of the nearest cutting tooth, measured
generally
6c
CA 02885473 2015-03-19
parallel to the longitudinal axis, and a distance between the tips of adjacent
cutting teeth,
measured generally parallel to the longitudinal axis, is approximately 2Ø
26. The reciprocating saw blade of clause 15, wherein the plunge point
includes a
second tooth positioned in the leading gullet adjacent the leading tooth, and
wherein the
second tooth is spaced apart from the plane.
27. A reciprocating saw blade for use with a reciprocating saw, the
reciprocating saw
blade comprising:
a body having a first end portion and a second end portion, the body defining
a
longitudinal axis;
an attachment portion coupled to the first end portion of the body, the
attachment
portion including a tang and an aperture configured to couple to the
reciprocating saw;
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a rake face extending from
the tip generally
toward the longitudinal axis and defining a gullet, and a relief surface
extending from the
tip generally toward the second end portion of the body; and
a plunge point formed on the second end portion of the body for initiating a
plunge
cut, the plunge point including a leading tooth and a second tooth, the
leading tooth
including a tip and a rake face extending from the tip generally toward the
longitudinal axis
and defining a leading gullet, the leading gullet being at least twice as
large as each gullet
of the plurality of cutting teeth, the second tooth being positioned in the
leading gullet
adjacent the leading tooth and being generally smaller than the leading tooth
and each of
the plurality of cutting teeth;
wherein the tips of the plurality of cutting teeth and the tip of the leading
tooth
define a plane that is generally parallel to the longitudinal axis, wherein a
first angle
between the plane and the rake face of the leading tooth, measured through the
leading
tooth, is greater than 90 degrees, and wherein a second angle between the
plane and the
rake face of each cutting tooth, measured through the corresponding cutting
tooth, is less
than 90 degrees.
28. The reciprocating saw blade of clause 27, wherein the first angle is
approximately
95 to 105 degrees.
6d
CA 02885473 2015-03-19
29. The reciprocating saw blade of clause 27, wherein the second angle is
approximately 80 to 88 degrees.
30. The reciprocating saw blade of clause 27, wherein the second tooth is
spaced apart
from the plane.
31. The reciprocating saw blade of clause 27, wherein each cutting tooth
has a first
utmost width measured generally parallel to the longitudinal axis, the leading
tooth has a
second utmost width measured generally parallel to the longitudinal axis, and
the second
tooth has a third utmost width measured generally parallel to the longitudinal
axis, and
wherein the third utmost width is less than the second utmost width and the
second utmost
width is less than the first utmost width.
32. The reciprocating saw blade of clause 27, wherein the leading gullet is
approximately four times larger than each gullet of the plurality of cutting
teeth.
33. The reciprocating saw blade of clause 27, wherein a ratio between a
distance from
the tip of the leading tooth to the tip of the nearest cutting tooth, measured
generally
parallel to the longitudinal axis, and a distance between the tips of adjacent
cutting teeth,
measured generally parallel to the longitudinal axis, is approximately 2Ø
34. The reciprocating saw blade of clause 27, wherein the second tooth
includes a tip,
and wherein a ratio between a distance from the tip of the leading tooth to
the tip of the
nearest cutting tooth, measured generally parallel to the longitudinal axis,
and a distance
from the tip of the leading tooth to the tip of the second tooth, measured
generally parallel
to the longitudinal axis, is approximately 6.6.
35. The reciprocating saw blade of clause 27, wherein the second tooth
includes a tip,
and wherein a ratio between a distance from the tip of the leading tooth to
the tip of the
second tooth, measured generally parallel to the longitudinal axis, and a
distance between
the tips of adjacent cutting teeth, measured generally parallel to the
longitudinal axis, is
approximately 0.3.
36. The reciprocating saw blade of clause 27, wherein the second tooth is
generally V-
shaped.
6e
CA 02885473 2015-03-19
37. The reciprocating saw blade of clause 27, wherein the second tooth
includes a tip, a
rake face extending generally toward the longitudinal axis, and a relief
surface extending
generally toward the leading tooth, and wherein a third angle between the
plane and the
rake face of the second tooth, measured through the second tooth, is greater
than 90
degrees.
38. The reciprocating saw blade of clause 37, wherein the third angle is
approximately
95 to 105 degrees.
39. A reciprocating saw blade for use with a reciprocating saw, the
reciprocating saw
blade configured to cut a work piece having a nail extending therethrough, the
reciprocating
saw blade comprising:
a body defining a longitudinal axis;
an attachment portion coupled to the body, the attachment portion including a
tang
and an aperture configured to couple to the reciprocating saw; and
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a rake face extending from
the tip generally
toward the longitudinal axis and at least partially defining a gullet, a
relief surface
extending from the tip and having a first end that is closer to the attachment
portion and a
second end that is further from the attachment portion, and a protrusion
extending from the
second end of the relief surface, the protrusion of each cutting tooth
inhibiting the nail from
entering the gullet and contacting the rake face of an adjacent cutting tooth
during cutting
operations.
40. The reciprocating saw blade of clause 39, wherein the tips of the
plurality of cutting
teeth define a plane that is generally parallel to the longitudinal axis, and
wherein the
protrusions of the plurality of cutting teeth are spaced apart from the plane.
41. The reciprocating saw blade of clause 39, wherein the protrusions of
the plurality of
cutting teeth do not cut the work piece during cutting operations.
42. The reciprocating saw blade of clause 39, wherein the protrusion of
each cutting
tooth is generally rounded.
43. The reciprocating saw of clause 39, wherein the gullet of each cutting
tooth includes
a base, and wherein a ratio between a distance from the base of the gullet to
an apex of the
6f
CA 02885473 2015-03-19
protrusion, measured generally perpendicular to the longitudinal axis, and a
distance from
the base of the gullet to the tip, measured generally perpendicular to the
longitudinal axis,
of each cutting tooth is approximately 0.68.
44. The reciprocating saw of clause 39, wherein a ratio between a distance
from the
protrusion to the tip of the one cutting tooth, measured generally parallel to
the longitudinal
axis, and a distance from the protrusion of the one cutting tooth and the tip
of an adjacent
cutting tooth, measured generally parallel to the longitudinal axis, is
approximately 1.5.
45. The reciprocating saw blade of clause 39, further comprising a plunge
point formed
on the body opposite the attachment portion for initiating a plunge cut.
46. The reciprocating saw blade of clause 45, wherein the plunge point
includes a
leading tooth having a tip and defining a leading gullet between the leading
tooth and the
plurality of cutting teeth, and wherein the leading gullet is larger than the
gullets of the
plurality of cutting teeth.
47. The reciprocating saw blade of clause 46, wherein the plunge point
further includes
a second tooth positioned in the leading gullet adjacent the leading tooth,
wherein the tips
of the plurality of cutting teeth and the tip of the leading tooth define a
plane that is
generally parallel to the longitudinal axis, and wherein the second tooth is
spaced apart
from the plane.
48. A reciprocating saw blade for use with a reciprocating saw, the
reciprocating saw
blade comprising:
a body defining a longitudinal axis;
an attachment portion coupled to the body, the attachment portion including a
tang
and an aperture configured to couple to the reciprocating saw; and
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a relief surface extending
from the tip, and
a protrusion extending from an end of the relief surface opposite the tip;
wherein the tips of the plurality of cutting teeth define a first plane that
is generally
parallel to the longitudinal axis and the protrusions of the plurality of
cutting teeth define a
second plane that is generally parallel to the longitudinal axis, and wherein
a distance
between the first plane and the second plane is at most approximately 0.035
inches.
6g
CA 02885473 2015-03-19
49. The reciprocating saw blade of clause 48, wherein the distance between
the first
plane and the second plane is approximately 0.032 inches.
50. The reciprocating saw blade of clause 49, wherein a distance between
the protrusion
of one cutting tooth and the tip of an adjacent cutting tooth, measured
generally parallel to
the longitudinal axis, is approximately 0.08 inches.
51. The reciprocating saw blade of clause 48, wherein the reciprocating saw
blade is
configured to cut a work piece having a nail extending therethrough, wherein
each cutting
tooth includes a rake face extending from the tip generally toward the
longitudinal axis and
at least partially defining a gullet, and wherein the protrusion of each
cutting tooth inhibits
the nail from entering the gullet and contacting the rake face of an adjacent
cutting tooth
during cutting operations.
52. The reciprocating saw blade of clause 48, wherein adjacent cutting
teeth of the
plurality of cutting teeth are separated by a pitch of approximately 0.2
inches.
53. The reciprocating saw blade of clause 48, wherein the protrusion of
each cutting
tooth is generally rounded.
54. The reciprocating saw blade of clause 48, wherein the relief surface of
each cutting
tooth includes a first end that is closer to the attachment portion and a
second end that is
further from the attachment portion, and wherein the tip of each cutting tooth
is formed at
the first end of the relief surface and the protrusion of each cutting tooth
extends from the
second end of the relief surface.
55. A reciprocating saw blade for use with a reciprocating saw, the
reciprocating saw
blade comprising:
a body defining a longitudinal axis;
an attachment portion coupled to the body, the attachment portion including a
tang
and an aperture configured to couple to the reciprocating saw; and
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a relief surface extending
from the tip, and
a protrusion extending from an end of the relief surface opposite the tip,
each cutting tooth
defining an effective relief surface that extends from the tip and is tangent
to the protrusion;
6h
CA 02885473 2015-03-19
wherein a distance between effective relief surfaces of adjacent cutting teeth
is at
most approximately 0.06 inches.
56. The reciprocating saw blade of clause 55, wherein the distance between
effective
relief surfaces of adjacent cutting teeth is approximately 0.05 inches.
57. The reciprocating saw blade of clause 55, wherein the tips of the
plurality of cutting
teeth define a plane that is generally parallel to the longitudinal axis, and
wherein the
effective relief surface of each cutting tooth intersects the plane at an
angle of
approximately 14.5 degrees.
58. The reciprocating saw blade of clause 55, wherein the reciprocating saw
blade is
configured to cut a work piece having a nail extending theretluough, wherein
each cutting
tooth includes a rake face extending from the tip generally toward the
longitudinal axis and
at least partially defining a gullet, and wherein the protrusion of each
cutting tooth inhibits
the nail from entering the gullet and contacting the rake face of an adjacent
cutting tooth
during cutting operations.
59. The reciprocating saw blade of clause 55, wherein adjacent cutting
teeth of the
plurality of cutting teeth are separated by a pitch of approximately 0.2
inches.
60. The reciprocating saw blade of clause 55, wherein the protrusion of
each cutting
tooth is generally rounded.
61. The reciprocating saw blade of clause 55, wherein the relief surface of
each cutting
tooth includes a first end that is closer to the attachment portion and a
second end that is
further from the attachment portion, and wherein the tip of each cutting tooth
is formed at
the first end of the relief surface and the protrusion of each cutting tooth
extends from the
second end of the relief surface.
62. The reciprocating saw blade of clause 61, wherein the relief surface of
each cutting
tooth extends approximately 0.1 inches from the first end to the second end.
63. A reciprocating saw blade for use with a reciprocating saw, the
reciprocating saw
blade comprising:
a body defining a longitudinal axis;
6i
CA 02885473 2015-03-19
an attachment portion coupled to the body, the attachment portion including a
tang
and an aperture configured to couple to the reciprocating saw, the attachment
portion being
angled relative to the longitudinal axis by a tang angle; and
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a relief surface extending
from the tip, and
a protrusion extending from an end of the relief surface opposite the tip,
each cutting tooth
defining an effective relief surface that extends from the tip and is tangent
to the protrusion;
wherein the tips of the plurality of cutting teeth define a plane that is
generally
parallel to the longitudinal axis, wherein the relief surface of each cutting
tooth intersects
the plane at a relief angle and the effective relief surface of each cutting
tooth intersects the
plane at an effective relief angle, and wherein the effective relief angle is
between the tang
angle and the relief angle.
64. The reciprocating saw blade of clause 63, wherein the tang angle is
approximately
6.5 degrees and the relief angle of each cutting tooth is approximately 23
degrees.
65. The reciprocating saw blade of clause 64, wherein the effective relief
angle of each
cutting tooth is approximately 14.5 degrees.
66. The reciprocating saw blade of clause 63, wherein a ratio between the
relief angle
and the effective relief angle of each cutting tooth is approximately 1.6.
67. The reciprocating saw blade of clause 63, wherein a ratio between the
effective
relief angle, in degrees, of each cutting tooth and a distance, in inches,
between effective
relief surfaces of adjacent cutting teeth is approximately 290.
68. The reciprocating saw blade of clause 63, wherein a ratio between a
distance from
the protrusion of one cutting tooth to the tip of an adjacent cutting tooth,
measured
generally parallel to the longitudinal axis, and a distance between effective
relief surfaces
of adjacent cutting teeth is approximately 1.6.
69. The reciprocating saw blade of clause 63, wherein the reciprocating saw
blade is
configured to cut a work piece having a nail extending therethrough, wherein
each cutting
tooth includes a rake face extending from the tip generally toward the
longitudinal axis and
at least partially defining a gullet, and wherein the protrusion of each
cutting tooth inhibits
6j
CA 02885473 2015-03-19
the nail from entering the gullet and contacting the rake face of an adjacent
cutting tooth
during cutting operations.
70. The reciprocating saw blade of clause 63, wherein adjacent cutting
teeth of the
plurality of cutting teeth are separated by a pitch of approximately 0.2
inches.
71. The reciprocating saw blade of clause 63, wherein the protrusion of
each cutting
tooth is generally rounded.
72. The reciprocating saw blade of clause 63, wherein the relief surface of
each cutting
tooth includes a first end that is closer to the attachment portion and a
second end that is
further from the attachment portion, and wherein the tip of each cutting tooth
is formed at
the first end of the relief surface and the protrusion of each cutting tooth
extends from the
second end of the relief surface.
73. A reciprocating saw blade for use with a reciprocating saw, the
reciprocating saw
blade configured to cut a work piece having a nail extending therethrough, the
reciprocating
saw blade comprising:
a body defining a longitudinal axis;
an attachment portion coupled to the body, the attachment portion including a
tang
and an aperture configured to couple to the reciprocating saw, the attachment
portion being
angled relative to the longitudinal axis by a tang angle; and
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a rake face extending from
the tip generally
toward the longitudinal axis and at least partially defining a gullet, a
relief surface
extending from the tip, and a protrusion extending from an end of the relief
surface
opposite the tip, the protrusion of each cutting tooth inhibiting the nail
from entering the
gullet and contacting the rake face of an adjacent cutting tooth during
cutting operations,
each cutting tooth defining an effective relief surface that extends from the
tip and is
tangent to the protrusion;
wherein the tips of the plurality of cutting teeth define a first plane that
is generally
parallel to the longitudinal axis and the protrusions of the plurality of
cutting teeth define a
second plane that is generally parallel to the longitudinal axis, wherein a
distance between
the first plane and the second plane is at most approximately 0.035 inches;
6k
CA 02885473 2016-08-26
wherein a distance between effective relief surfaces of adjacent cutting teeth
is at
most approximately 0.06 inches; and
wherein the relief surface of each cutting tooth intersects the first plane at
a relief
angle and the effective relief surface of each cutting tooth intersects the
first plane at an
effective relief angle, and wherein the effective relief angle is between the
tang angle and
the relief angle.
74. The reciprocating saw blade of clause 73, wherein the distance between
the first
plane and the second plane is approximately 0.032 inches.
75. The reciprocating saw blade of clause 74, wherein a distance between
the protrusion
of one cutting tooth and the tip of an adjacent cutting tooth, measured
generally parallel to
the longitudinal axis, is approximately 0.08 inches.
76. The reciprocating saw blade of clause 73, wherein the distance between
effective
relief surfaces of adjacent cutting teeth is approximately 0.05 inches.
77. The reciprocating saw blade of clause 73, wherein the tang angle is
approximately
6.5 degrees and the relief angle of each cutting tooth is approximately 23
degrees.
78. The reciprocating saw blade of clause 77, wherein the effective relief
angle of each
cutting tooth is approximately 14.5 degrees.
79. The reciprocating saw blade of clause 73, wherein adjacent cutting
teeth of the
plurality of cutting teeth are separated by a pitch of approximately 0.2
inches.
80. The reciprocating saw blade of clause 73, wherein the protrusion of
each cutting
tooth is generally rounded.
According to one aspect of the present invention there is provided a
reciprocating saw blade for use with a reciprocating saw, the reciprocating
saw blade
configured to cut a work piece having a nail extending therethrough, the
reciprocating saw
blade comprising:
a body defining a longitudinal axis;
an attachment portion coupled to the body, the attachment portion including a
tang and an aperture configured to couple to the reciprocating saw; and
61
CA 02885473 2016-08-26
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a rake face extending from
the tip generally
toward the longitudinal axis and at least partially defining a gullet, a
relief surface
extending from the tip and having a first end that is closer to the attachment
portion and a
second end that is further from the attachment portion, and a protrusion
extending from the
second end of the relief surface, the protrusion of each cutting tooth
inhibiting the nail from
entering the gullet and contacting the rake face of an adjacent cutting tooth
during cutting
operations;
wherein the tips of the plurality of cutting teeth define a first plane that
is
generally parallel to the longitudinal axis and the protrusions of the
plurality of cutting teeth
define a second plane that is generally parallel to the longitudinal axis, and
wherein a
distance between the first plane and the second plane is at most 0.035 inches;
and
wherein a distance between the protrusion of one cutting tooth and the tip of
an
adjacent cutting tooth, measured generally parallel to the longitudinal axis,
is 0.08 inches.
According to a further aspect of the present invention there is provided a
reciprocating saw blade for use with a reciprocating saw, the reciprocating
saw blade
comprising:
a body defining a longitudinal axis;
an attachment portion coupled to the body, the attachment portion including a
tang and an aperture configured to couple to the reciprocating saw; and
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a relief surface extending
from the tip, and
a protrusion extending from an end of the relief surface opposite the tip;
wherein the tips of the plurality of cutting teeth define a first plane that
is
generally parallel to the longitudinal axis and the protrusions of the
plurality of cutting teeth
define a second plane that is generally parallel to the longitudinal axis, and
wherein a
distance between the first plane and the second plane is at most approximately
0.035
inches;
wherein a distance between the protrusion of one cutting tooth and the tip of
an
adjacent cutting tooth, measured generally parallel to the longitudinal axis,
is approximately
0.08 inches.
6m
CA 02885473 2016-08-26
According to another aspect of the present invention there is provided a
reciprocating saw blade for use with a reciprocating saw, the reciprocating
saw blade
comprising:
a body defining a longitudinal axis;
an attachment portion coupled to the body, the attachment portion including a
tang and an aperture configured to couple to the reciprocating saw; and
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a relief surface extending
from the tip, and
a protrusion extending from an end of the relief surface opposite the tip,
each cutting tooth
defining an effective relief surface that extends from the tip and is tangent
to the protrusion;
wherein the tips of the plurality of cutting teeth define a plane that is
generally
parallel to the longitudinal axis, and wherein the effective relief surface of
each cutting
tooth intersects the plane at an angle of approximately 14.5 degrees, and
wherein a distance
between effective relief surfaces of adjacent cutting teeth, measured
perpendicular to the
effective relief surfaces, is at most approximately 0.06 inches.
According to yet another aspect of the present invention there is provided a
reciprocating saw blade for use with a reciprocating saw, the reciprocating
saw blade
comprising:
a body defining a longitudinal axis;
an attachment portion coupled to the body, the attachment portion including a
tang and an aperture configured to couple to the reciprocating saw, the
attachment portion
being angled relative to the longitudinal axis by a tang angle; and
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a relief surface extending
from the tip, and
a protrusion extending from an end of the relief surface opposite the tip,
each cutting tooth
defining an effective relief surface that extends from the tip and is tangent
to the protrusion;
wherein the tips of the plurality of cutting teeth define a plane that is
generally
parallel to the longitudinal axis, wherein the relief surface of each cutting
tooth intersects
the plane at a relief angle and the effective relief surface of each cutting
tooth intersects the
plane at an effective relief angle, and wherein a value of the effective
relief angle is
between a value of the tang angle and a value of the relief angle.
6n
CA 02885473 2016-08-26
According to still another aspect of the present invention there is provided a
reciprocating saw blade for use with a reciprocating saw, the reciprocating
saw blade
configured to cut a work piece having a nail extending therethrough, the
reciprocating saw
blade comprising:
a body defining a longitudinal axis;
an attachment portion coupled to the body, the attachment portion including a
tang and an aperture configured to couple to the reciprocating saw, the
attachment portion
being angled relative to the longitudinal axis by a tang angle; and
a cutting portion formed on the body, the cutting portion including a
plurality of
cutting teeth, each cutting tooth including a tip, a rake face extending from
the tip generally
toward the longitudinal axis and at least partially defining a gullet, a
relief surface
extending from the tip, and a protrusion extending from an end of the relief
surface
opposite the tip, the protrusion of each cutting tooth inhibiting the nail
from entering the
gullet and contacting the rake face of an adjacent cutting tooth during
cutting operations,
each cutting tooth defining an effective relief surface that extends from the
tip and is
tangent to the protrusion;
wherein the tips of the plurality of cutting teeth define a first plane that
is
generally parallel to the longitudinal axis and the protrusions of the
plurality of cutting teeth
define a second plane that is generally parallel to the longitudinal axis,
wherein a distance
between the first plane and the second plane is at most approximately 0.035
inches;
wherein the effective relief angle of each cutting tooth is approximately 14.5
degrees, wherein a distance between effective relief surfaces of adjacent
cutting teeth,
measured perpendicular to the effective relief surfaces, is at most
approximately 006
inches; and
wherein the relief surface of each cutting tooth intersects the first plane at
a
relief angle and the effective relief surface of each cutting tooth intersects
the first plane at
an effective relief angle, and wherein a value of the effective relief angle
is between a value
of the tang angle and a value of the relief angle.
[0013] Other aspects of the invention will become apparent by consideration
of the
detailed description and accompanying drawings.
6o
CA 02885473 2016-08-26
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Fig. 1 is a perspective view of a saw blade according to one
embodiment of the
invention.
[0015] Fig. 2 is a side view of the saw blade shown in Fig. 1.
[0016] Fig. 3 is an enlarged side view of a portion of the saw blade shown
in Fig. 1.
[0017] Fig. 4 is an enlarged side view of the portion of the saw blade
shown in Fig. 4,
the saw blade cutting through a work piece having a nail extending
therethrough.
[0018] Fig. 5 is a side view of a saw blade according to another embodiment
of the
invention.
[0019] Fig. 6 is an enlarged side view of a portion of the saw blade shown
in Fig. 5.
[0020] Fig. 7 is an enlarged side view of a portion of a saw blade
according to yet
another embodiment of the invention.
[0021] Fig. 8 is a side view of a saw blade according to another embodiment
of the
invention.
[0022] Fig. 9 is an enlarged side view of a portion of the saw blade shown
in Fig. 8.
6p
CA 02885473 2015-03-19
WO 2011/133864
PCT/US2011/033583
[0023] Fig. 10 is a side view of a saw blade according to another
embodiment of the
invention.
[0024] Fig. 11 is an enlarged side view of a portion of the saw blade shown
in Fig. 10.
[0025] Fig. 12 is a side view of a saw blade according to another
embodiment of the
invention.
[0026] Fig. 13 is an enlarged side view of a portion of the saw blade shown
in Fig. 12.
[0027] Fig. 14 is a side view of a saw blade according to another
embodiment of the
invention.
[0028] Fig. 15 is an enlarged side view of a portion of the saw blade shown
in Fig. 14.
10029] Fig. 16 is a side view of a saw blade according to another
embodiment of the
invention.
[0030] Fig. 17 is an enlarged side view of a portion of the saw blade shown
in Fig. 16.
[0031] Fig. 18 is a side view of a saw blade according to another
embodiment of the
invention.
[0032] Fig. 19 is an enlarged side view of a portion of the saw blade shown
in Fig. 18.
[0033] Fig. 20 is a side view of a saw blade according to another
embodiment of the
invention.
[0034] Fig. 21 is an enlarged side view of a portion of the saw blade shown
in Fig. 20.
100351 Fig. 22 is a side view of a saw blade according to another
embodiment of the
invention.
[0036] Fig. 23 is an enlarged side view of a portion of the saw blade shown
in Fig. 22.
[0037] Fig. 24 is a side view of a saw blade according to another
embodiment of the
invention.
7
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
[0038] Fig. 25 is an enlarged side view of a portion of the saw blade shown
in Fig. 24.
[0039] Fig. 26 is a side view of a saw blade according to another
embodiment of the
invention.
[0040] Fig. 27 is an enlarged side view of a portion of the saw blade shown
in Fig. 26.
[0041] Fig. 28 is a perspective view of a reciprocating saw.
[0042] Before any embodiments of the invention are explained in detail, it
is to be
understood that the invention is not limited in its application to the details
of construction and the
arrangement of components set forth in the following description or
illustrated in the following
drawings. The invention is capable of other embodiments and of being practiced
or of being
carried out in various ways.
DETAILED DESCRIPTION
[0043] Figs. 1-3 illustrate a saw blade 30 according to one embodiment of
the invention.
The illustrated saw blade 30 is a reciprocating saw blade for use with a power
tool such as, for
example, a reciprocating saw 34 (Fig. 28). The saw blade 30 includes a body
38, an attachment
portion 42 for coupling the blade 30 to the reciprocating saw 34, a cutting
portion 46 having a
plurality of cutting teeth 50, and a plunge point 54 for initiating a plunge
cut. In the illustrated
embodiment, the body 38, the attachment portion 42, the cutting portion 46,
and the plunge point
54 are all integrally formed as a single piece such that the saw blade 30 is a
unitary structure. In
other embodiments, the saw blade 30 may be formed from several pieces that are
welded or
otherwise secured together. During operation, the saw blade 30 is reciprocated
in a cutting
direction 58 and a return direction 62 (Fig. 2) to cut through a work piece.
In some
embodiments, the saw 34 and the blade 30 may be used to cut through work
pieces composed of
wood having nails extending through or embedded therein.
[0044] The body 38 includes a first end portion 66 and a second end portion
70. The
attachment portion 42 is coupled to (e.g., formed at) the first end portion 66
of the body 38 and
the plunge point 54 is coupled to (e.g., formed at) the second end portion 70
of the body 38. A
back portion 74 extends between the attachment portion 42 and the plunge point
54 on a side of
8
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
the body 38 opposite the cutting portion 46. The illustrated back portion 74
includes four
stepped surfaces 78, 82, 86, 90 at different distances from the cutting
portion 46. The body 38
also defines a longitudinal axis 94 (Figs. 2 and 3) extending through the
first end portion 66 and
the second end portion 70.
[0045] The attachment portion 42 extends from the first end portion 66 of
the body 38 and
includes a tang 98 and an aperture 102. The tang 98 and the aperture 102 are
configured to
engage a blade clamp of a reciprocating saw to securely and releasably couple
the blade 30 to the
saw. As shown in Fig. 2, the illustrated attachment portion 42 is angled
relative to the
longitudinal axis 94 by a tang angle A. In the illustrated embodiment, the
tang angle A is
approximately 6.5 degrees. In other embodiments, the tang angle A may be
larger or smaller.
[0046] Referring to Figs. 2 and 3, the cutting teeth 50 define a tooth form
on the body 38.
The illustrated tooth form includes five teeth per inch (TPI) such that
adjacent cutting teeth 50
are separated by a pitch P of 0.2 inches. In other embodiments, the saw blade
30 may include
fewer or more teeth per inch. For example, the tooth form may include 4 TPI, 6
TPI, or the like.
In the illustrated embodiment, the cutting teeth 50 are unset such that the
teeth 50 extend straight
from the body 38. In other embodiments, some or all of the teeth 50 may be
bent or "set" at
various angles relative to a hypothetical plane defined by the body 38. The
distances and angles
identified herein refer to a saw blade in which the cutting teeth are unset.
However, it should be
readily apparent that a saw blade may be designed according to the disclosed
dimensions with
unset cutting teeth, and the cutting teeth may ultimately be set as desired
during manufacture.
[0047] As shown in Fig. 3, each cutting tooth 50 includes a tip 106, a rake
face 110
extending from the tip 106 generally toward the longitudinal axis 94 and at
least partially
defining a gullet 114, a relief surface 118 extending from the tip 106 and
having a first end 122
that is closer to the attachment portion 42 and a second end 126 that is
further from the
attachment portion 42, and a protrusion 130 extending from the second end 126
of the relief
surface 118. The tips 106 of the cutting teeth define a plane 134 that is
generally parallel to the
longitudinal axis 94.
[0048] Each rake face 110 extends from the corresponding tip 106 at a rake
angle B relative
to the plane 134. The rake angle B of each cutting tooth 50, measured through
the corresponding
9
CA 02 885473 2 015-03-1 9
WO 2011/133864 PCT/US2011/033583
cutting tooth 50, is a positive rake angle (i.e., less than 90 degrees). In
the illustrated
embodiment, the rake angle B of each cutting tooth is approximately 80 to 88
degrees. In other
embodiments, the rake angle B may be larger or smaller, or each rake face 110
may extend at a
'negative rake angle' (i.e., greater than 90 degrees relative to the plane
134).
[0049] The gullet 114 of each cutting tooth 50 is defined by the rake face
110 of the cutting
tooth 50 and a gullet surface 138. Each gullet surface 138 extends from the
corresponding rake
face 110 to the protrusion 130 of an adjacent tooth 50 and includes a base
142. The gullet
surfaces 138 are defined by a first gullet radius ri, a second gullet radius
r2, and a third gullet
radius r3. In the illustrated embodiment, the first gullet radius r1 is
approximately 0.021 inches,
the second gullet radius r2 is approximately 0.035 inches, and the third
gullet radius r3 is
approximately 0.040 inches. The gullet 114 of each tooth 50 also has a gullet
depth L, or tooth
height, measured from the base 142 of the gullet 114 to the tip 106 of the
tooth 50. In the
illustrated embodiment, the gullet depth L is approximately 0.1 inches.
[0050] The relief surface 118 of each cutting tooth 50 extends generally
toward the
longitudinal axis 94 and toward the plunge point 54. The relief surfaces 118
are oriented at relief
angles C relative to the plane 134. In the illustrated embodiment, the relief
angle C of each
cutting tooth 50 is approximately 23 degrees. In other embodiments, the relief
angles C may be
larger or smaller. Each relief surface 118 has a relief length M measured from
the first end 122
(e.g., the tip 106) to the second end 126 (e.g., a beginning of the protrusion
130). In the
illustrated embodiment, the relief length M of each cutting tooth 50 is
approximately 0.1 inches.
In other embodiments, the relief length M may be larger or smaller.
[0051] The relief surface 118 of each cutting tooth 50 is interrupted by
the protrusion 130
extending from the second end 126 of the relief surface 118. In some
embodiments, the
protrusion 130 at the cutting tooth 50 nearest the plunge point 54 may be
omitted. The
protrusion 130 of each tooth 50 is defined by a first protrusion radius r4
that transitions from the
relief surface 118, a first protrusion face 146 that extends from the first
protrusion radius r4, an
apex 150 that extends from the first protrusion face 146 and has a second
protrusion radius r5,
and a second protrusion face 154 extending from the apex 150 to the gullet
surface 138. In the
illustrated embodiment, the apex 150 of each protrusion 130 is curved such
that the protrusions
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
130 are generally rounded. In other embodiments, the protrusions 130 may have
other shapes or
forms. The second protrusion face 154 is disposed at an internal protrusion
angle D relative to
the first protrusion face 146 and is disposed at a rear protrusion angle E
relative to the plane 134.
In the illustrated embodiment, the first protrusion radius r4 is approximately
0.012 inches, the
second protrusion radius r5 is approximately 0.010 inches, the internal
protrusion angle D is
approximately 70 degrees, and the rear protrusion angle E is approximately 80
degrees.
[0052] With continued reference to Fig. 3, the protrusion 130 of each
cutting tooth 50 is
spaced a first distance N, measured generally parallel to the longitudinal
axis 94, from the tip 106
of the corresponding cutting tooth 50. The protrusion 130 of each cutting
tooth 50 is spaced a
second distance 0, measured generally parallel to the longitudinal axis 94,
from the tip 106 of an
adjacent cutting tooth 50. The second distance 0 also represents a width of
the gullet 114. In
some embodiments, a ratio between the first distance N and the second distance
0 is
approximately 1.5. In the illustrated embodiment, the first distance N is
approximately 0.12
inches and the second distance 0 is approximately 0.08 inches.
[0053] The apex 150 of the protrusion 130 is spaced a distance Q, measured
generally
perpendicular to the longitudinal axis 94, from the base 142 of the gullet
114. In some
embodiments, a ratio between the distance Q from the base 142 of the gullet
114 to the apex 150
of the protrusion 130 and the distance L from the base 142 of the gullet 114
to the tip 106 of the
cutting tooth 50 is approximately 0.68. In the illustrated embodiment, the
distance Q is
approximately 0.068 inches.
[0054] The protrusions 130 of the cutting teeth 50 define a plane 158 that
is generally
parallel to the longitudinal axis 94 and to the plane 134 defined by the tips
106 of the cutting
teeth 50. In some embodiments, a distance R between the plane 134 defined by
the tips 106 and
the plane 158 defined by the protnisions 130 is at most approximately 0.035
inches. In the
illustrated embodiment, the distance R is approximately 0.032 inches. Such an
arrangement
helps inhibit nails from entering the gullets 114 of the cutting teeth 50
during cutting operations,
as further discussed below.
[0055] Each cutting tooth 50 also defines an effective relief surface 162
that extends from the
tip 106 of the cutting tooth 50 and is tangent to the adjacent/respective
protrusion 130. Each
11
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
effective relief surface 162 intersects the plane 134 defined by the tips 106
at an effective relief
angle F. In the illustrated embodiment, the effective relief angle F is
approximately 14.5
degrees. The effective relief angle F is between the tang angle A and the
relief angle C. That is,
the effective relief angle F of each cutting tooth 50 is generally greater
than the tang angle A
(e.g., 6.5 degrees), but generally smaller than the relief angle C (e.g., 23
degrees). In some
embodiments, a ratio between the relief angle C and the effective relief angle
F of each cutting
tooth 50 is approximately 1.6.
[00561 The effective relief surfaces 162 of adjacent cutting teeth 50 are
spaced apart from
each other by a distance S. In some embodiments, the distance S between
effective relief
surfaces 162 is at most approximately 0.06 inches. In the illustrated
embodiment, the distance S
is approximately 0.05 inches. Such an arrangement also helps inhibit nails
from entering the
gullets 114 of the cutting teeth 50 during cutting operations, as further
discussed below. In some
embodiments, a ratio between the effective relief angle F, in degrees, of each
cutting tooth 50
and the distance S, in inches, between effective relief surfaces 162 is
approximately 290.
Furthermore, in some embodiments, a ratio between the distance 0 from the
protrusion 130 of
one cutting tooth 50 to the tip 106 of an adjacent cutting tooth 50 and the
distance S between
effective relief surfaces 162 of adjacent cutting teeth 50 is approximately
1.6.
[0057] Referring to Fig. 4, the protrusions 130 of the cutting teeth 50
inhibit nails 166, or
other hard objects, imbedded in a work piece 170 from entering the gullets 114
and contacting
the rake faces 110 of the teeth 50 during cutting operations. As the saw blade
30 moves in the
cutting direction 58 (to the left in Fig. 4), the tips 106 of the cutting
teeth 50 engage and cut
through the work piece 170. The protrusions 130 are hidden behind the tips 106
of adjacent teeth
50 such that the protrusions 130 do not cut the work piece 170 during the
cutting operation.
[0058] When the saw blade 30 encounters the nail 166, the rake faces 110 of
the cutting teeth
50 typically would contact the nail 166. Such contact may chip, break, or
otherwise damage the
cutting teeth 50, significantly reducing the usable life of the saw blade 30.
However, as shown in
Fig. 4, the protrusions 130 inhibit the nail 166 from impacting the rake faces
110. Instead, as the
saw blade 30 moves in the cutting direction 58, the nail 166 contacts one of
the protrusions 130
before contacting the adjacent rake face 110. The protrusion 130 displaces
(e.g., lifts) the saw
12
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
blade 30, which repositions the nail 166 with respect to the gullet 114 in an
improved cutting
position. In the improved cutting position, the protrusion 130 inhibits the
nail 166 from entering
the gullet 114 and the tip 106 is allowed to cut into the nail 166. When the
saw blade 30 is
reciprocated in the return direction 62 (to the right in Fig. 4), the nail 166
can ride along the
corresponding relief surface 118 and over the tip 106.
[0059] In the illustrated embodiment, the protrusions 130 of the cutting
teeth 50 are designed
to inhibit a standard framing nail having a 0.131 inch diameter from entering
the gullets 114. In
other embodiments, the protrusions 130 may be optimized to inhibit other size
nails from
entering the gullets 114. The distance R between the plane 134 defined by the
tips 106 and the
plane 158 defined by the protrusions 130 and the distance S between effective
relief surfaces 162
of adjacent cutting teeth 50 are optimized to increase durability of the
cutting teeth 50 by
offsetting a center of the framing nail approximately 0.031 inches below the
plane 134. That is,
the protrusions 130 are sized and positioned to prevent approximately 80% of
the nail from
entering the area above the plane 134. Such a configuration results in an
increase in durability
compared to a similar saw blade without protrusions on the cutting teeth. As
used herein, the
term 'durability' refers to the average number of cuts a saw blade makes
before fracturing a
cutting tooth.
[0060] Referring back to Fig. 3, the plunge point 54 is formed on the
second end portion 70
of the body 38 opposite the attachment portion 42. The illustrated plunge
point 54 includes a
leading tooth 174 and a second tooth 178. The leading tooth 174 includes a tip
182, a rake face
186 extending from the tip 182 generally toward the longitudinal axis 94 and
at least partially
defining a leading gullet 190, and a relief surface 194 extending from the tip
182 to an end 198
of the body 38. In the illustrated embodiment, the end 198 of the body 38 is
generally rounded.
In other embodiments, the end 198 of the body 38 may be, for example, a sharp
point or a flat
edge. A top edge 202 extends from the end 198 to the back portion 74 of the
body 38. The top
edge 202 is oriented at an angle G relative to the back portion 74 (e.g.,
relative to the fourth
stepped surface 90). In the some embodiments, the angle G may be approximately
5 to 50
degrees. In the illustrated embodiment, the angle G is approximately 40
degrees.
13
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
[0061] The tip 182 of the leading tooth 174 extends to the plane 134
defined by the tips 106
of the cutting teeth 50 to help define the plane 134. The rake face 186
extends from the tip 182
at a leading rake angle H relative to the plane 134. The leading rake angle H,
measured through
the leading tooth 174, is a negative rake angle (i.e., greater than 90
degrees) such that the leading
tooth 174 is a negative rake tooth. A negative rake tooth is less likely to
hook or grab material
being cut, allowing the plunge point 54 to more easily penetrate a work piece
without chipping
the work piece. In the illustrated embodiment, the leading rake angle H is
approximately 95 to
105 degrees. In other embodiments, the leading rake angle H may be larger or
smaller, or the
rake face 186 may extend at a positive rake angle relative to the plane 134.
[0062] The relief surface 194 of the leading tooth 174 extends from the tip
182 at a leading
relief angle I relative to the plane 134. In some embodiments, the leading
relief angle I is less
than 90 degrees. In other embodiments, the leading relief angle I is greater
than 45 degrees. In
the illustrated embodiment, the leading relief angle I is approximately 55 to
65 degrees.
[0063] The leading gullet 190 is defined by the rake face 186 of the
leading tooth 174 and
extends to the nearest, or first, cutting tooth 50. As shown in Fig. 3, the
leading gullet 190 is
significantly larger than the gullets 114 of the cutting teeth 50 and has a
leading gullet width T.
In some embodiments, the leading gullet 174 is at least twice as large as each
gullet 114. In the
illustrated embodiment, the leading gullet 174 is approximately four times
larger than each gullet
114. As such, the leading tooth 174 is spaced further apart from the nearest
cutting tooth 50 than
the cutting teeth 50 are spaced apart from each other. In the illustrated
embodiment, a ratio
between a distance U from the tip 182 of the leading tooth 174 to the tip 106
of the nearest
cutting tooth 50, measured generally parallel to the longitudinal axis 94, and
the distance P
between the tips 106 of adjacent cutting teeth 50 (i.e., the tooth pitch) is
approximately 2Ø The
enlarged leading gullet 190 improves plunge cut performance by allowing the
leading tooth 174
to penetrate further into a work piece before the plurality of cutting teeth
50 engage the work
piece, thereby improving cut quality and finish. The enlarged leading gullet
190 also improves
cut speed by allowing for greater chip removal.
[0064] The illustrated second tooth 178 is generally V-shaped and includes
a tip 206, a rake
face 210 extending from the tip 206 generally toward the longitudinal axis 94,
and a relief
14
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
surface 214 extending from the tip 206 generally toward the leading tooth 174.
Similar to the
leading tooth 174, the rake face 210 of the second tooth 178 extends at a
negative rake angle J
(i.e., at an angle greater than 90 degrees) relative to the plane 134. In the
illustrated embodiment,
the rake angle J, measured through the second tooth, is approximately 95 to
105 degrees. In
other embodiments, the rake angle J may be larger or smaller, or the rake face
210 may extend at
a positive rake angle relative to the plane 134.
[0065] The second tooth 178 is positioned within the leading gullet 190
adjacent the leading
tooth 174 such that the second tooth 178 is closer to the leading tooth 174
than to the nearest
cutting tooth 50. In the illustrated embodiment, the tip 206 of the second
tooth 178 is spaced a
distance V, measured generally parallel to the longitudinal axis 94, from the
tip 182 of the
leading tooth 174. A ratio between the distance V from the tip 182 of the
leading tooth 174 to
the tip 206 of the second tooth 178 and the distance P between the tips 106 of
adjacent cutting
teeth 50 (i.e., the tooth pitch) is approximately 0.3. In addition, a ratio
between the distance U
from the tip 182 of the leading tooth 174 to the tip 106 of the nearest
cutting tooth 50 and the
distance V from the tip 182 of the leading tooth 174 to the tip 206 of the
second tooth 178 is
approximately 6.6. In other embodiments, these ratios may be relatively larger
or smaller.
[0066] The illustrated second tooth 178 is generally smaller than the
leading tooth 174 and
each of the cutting teeth 50. As shown in Fig. 3, the second tooth 178 extends
from the leading
gullet 190 and is spaced apart from the plane 134 defined by the tips 106 of
the cutting teeth 50.
In other words, the plane 134 does not intersect or extend through any portion
of the second
tooth 178. In the illustrated embodiment, the second tooth 178 extends less
than halfway from
the body 38 to the plane 134. In other embodiments, the second tooth 178 may
extend to a
position nearer the plane 134 such as, for example, three-quarters the
distance to the plane 134.
[0067] In addition, the second tooth 178 has an utmost width W that is less
than an utmost
width X of the leading tooth 174 and an utmost width Y of each cutting tooth
50. As used
herein, the term 'utmost width' refers to a measurement of a tooth that is
taken generally parallel
to the longitudinal axis 94 at the tooth's greatest or maximum dimension. In
the illustrated
embodiment, the utmost width X of the leading tooth 174 is also less than the
utmost width Y of
CA 02885473 2015-03-19
WO 2011/13386-1 PCT/US2011/033583
each cutting tooth 50. In other embodiments, the utmost width X of the leading
tooth 174 may
be the same or similar to the utmost width Y of each cutting tooth 50.
[0068] The second tooth 178 improves plunge cut performance by breaking up
chip material,
thereby reducing the load on the leading tooth 174 and facilitating chip
removal. Such an
arrangement also increases cutting speed and saw blade life. In the
illustrated embodiment, the
plunge point 54 includes a single second tooth 178 positioned within the
leading gullet 190. In
other embodiments, the plunge point 54 may include multiple second teeth
positioned within the
leading gullet 190. In such embodiments, one or more of the second teeth may
be set.
Additionally or alternatively, the second teeth may have different geometries
and/or sizes. In
still other embodiments, the second tooth 178 may be omitted from the plunge
point 54.
[0069] Figs. 5-6 illustrate a reciprocating saw blade 230 according to
another embodiment of
the invention. The illustrated saw blade 230 is similar to the saw blade 30
described above with
reference to Figs. 1-4, and similar parts have been given the same reference
numbers, plus 200.
[0070] The illustrated saw blade 230 includes a body 238, an attachment
portion 242 for
coupling the blade 230 to a reciprocating saw, a cutting portion 246 having a
plurality of cutting
teeth 250, and a plunge point 254 for initiating a plunge cut. Each of the
cutting teeth 250
includes a protrusion 330 that inhibits a nail from entering a gullet 314 and
contacting a rake face
310 of an adjacent cutting tooth 250. In the illustrated embodiment, a back
portion 274 of the
body 238 is formed with three stepped surfaces 278, 282, 286, rather than the
four stepped
surfaces 78, 82, 86, 90 shown in Figs. 1-2.
[0071] Fig. 7 illustrates a cutting portion 446 of a saw blade 430
according to another
embodiment of the invention. The illustrated saw blade 430 is similar to the
saw blade 30
described above with reference to Figs. 1-4, and similar parts have been given
the same reference
numbers plus 400.
[0072] The cutting portion 446 includes a plurality of cutting teeth 450.
Each cutting tooth
450 includes a protrusion 530 that inhibits a nail from entering a gullet 514
and contacting a rake
face 510 of an adjacent cutting tooth 450. Similar to the gullets 114 and the
protrusions 130
discussed above with reference to Figs. 1-4, each of the gullets 514 is
defined by three gullet
16
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
radii ri, r2, r3 and each of the protrusions 130 is defined by two protrusion
radii r4, r5. In the
illustrated embodiment, the first gullet radius r1 is approximately 0.021
inches, the second gullet
radius r2 is approximately 0.035 inches, the third gullet radius r3 is
approximately 0.040, the first
protrusion radius r4 is approximately 0.012 inches, and the second protrusion
radius r5 is
approximately 0.010 inches.
[0073] In addition, each cutting tooth 450 includes a relief surface 518
extending from a tip
506 of the tooth 450. The relief surfaces 518 are oriented at a relief angle C
relative to a plane
534 defined by the tips 506 of the cutting teeth 450. In the illustrated
embodiment, the relief
angle C of each cutting tooth 450 is approximately 26 degrees.
[0074] Figs. 8-9 illustrate a reciprocating saw blade 630 according to
another embodiment of
the invention. The illustrated saw blade 630 is similar to the saw blade 30
described above with
reference to Figs. 1-4, and similar parts have been given the same reference
numbers, plus 600.
[0075] The illustrated saw blade 630 includes a body 638, an attachment
portion 642 for
coupling the blade 630 to a reciprocating saw, a cutting portion 646 having a
plurality of cutting
teeth 650, and a plunge point 654 for initiating a plunge cut. Each of the
cutting teeth 650
includes a tip 706, a rake face 710 at least partially defining a gullet 714,
a relief surface 718, and
a protrusion 730. The protrusions 730 inhibit nails from entering the gullets
714 and contacting
the rake faces 710 of adjacent cutting teeth 650. Each rake face 710 extends
from the tip 706 at a
rake angle B relative to a plane 734 defined by the tips 706. In the
illustrated embodiment, the
rake angle B of each cutting tooth 650 is approximately 82 degrees. Each
relief surface 718 also
extends from the tip 706 at a relief angle C relative to the plane 734. In the
illustrated
embodiment, the relief angle C of each cutting tooth 650 is approximately 20
degrees.
[0076] Figs. 10-11 illustrate a reciprocating saw blade 830 according to
another embodiment
of the invention. The illustrated saw blade 830 is similar to the saw blade 30
described above
with reference to Figs. 1-4, and similar parts have been given the same
reference numbers, plus
800.
[0077] The illustrated saw blade 830 includes a body 838, an attachment
portion 842 for
coupling the blade 830 to a reciprocating saw, a cutting portion 846 having a
plurality of cutting
17
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
teeth 850, and a plunge point 854 for initiating a plunge cut. Each of the
cutting teeth 850
includes a protrusion 930 that inhibits a nail from entering a gullet 914 and
contacting a rake face
910 of an adjacent cutting tooth 850. Similar to the gullets 914 discussed
above with reference
to Figs. 1-4, each of the gullets 914 is defined by three gullet radii ri, r2,
r3. In the illustrated
embodiment, the first gullet radius ri is approximately 0.025 inches, the
second gullet radius r2 is
approximately 0.035 inches, and the third gullet radius r3 is approximately
0.040 inches.
[0078] Each of the illustrated protrusions 930 is defined by a first
protrusion radius r4, a
second protrusion radius r5, and a first intermediate surface 1018 extending
between the radii r4,
r5. The first intermediate surface 1018 is a generally planar surface. In the
illustrated
embodiment, the first protrusion radius r4 is approximately 0.010 inches, the
second protrusion
radius r5 is approximately 0.010 inches, and the length of the first
intermediate surface 1018 is
approximately 0.005 inches. Each of the protrusions 930 is also defined by a
first protrusion face
946 that extends from the second protrusion radius r5, an apex 950 that
extends from the first
protrusion face 946, and a second protrusion face 954 that extends from the
apex 950 and defines
the gullet 914. The apex 950 is further defined by a third protrusion radius
r6, a fourth protrusion
radius r7, and a second intermediate surface 1022 extending between the radii
r6, r7. The second
intermediate surface 1022 is a generally planar surface. In the illustrated
embodiment, the third
protrusion radius ro is approximately 0.010 inches, the fourth protrusion
radius r7 is
approximately 0.010 inches, and the length of the second intermediate surface
1022 is
approximately 0.005 inches.
[0079] Figs. 12-13 illustrate a reciprocating saw blade 1030 according to
another
embodiment of the invention. The illustrated saw blade 1030 is similar to the
saw blade 30
described above with reference to Figs. 1-4, and similar parts have been given
the same reference
numbers, plus 1000.
[0080] The illustrated saw blade 1030 includes a body 1038, an attachment
portion 1042 for
coupling the blade 1030 to a reciprocating saw, a cutting portion 1046 having
a plurality of
cutting teeth 1050, and a plunge point 1054 for initiating a plunge cut. Each
of the cutting teeth
1050 includes a protrusion 1130 that inhibits a nail from entering a gullet
1114 and contacting a
rake face 1110 of an adjacent cutting tooth 1050. Similar to the gullets 1114
discussed above
18
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
with reference to Figs. 1-4, each of the gullets 1114 is defined by three
gullet radii r1, r2, r3. In
the illustrated embodiment, the first gullet radius r1 is approximately 0.030
inches, the second
gullet radius r2 is approximately 0.035 inches, and the third gullet radius r3
is approximately
0.040 inches.
[0081] Each of the illustrated protrusions 1130 is defined by a first
protrusion face 1146
extending from a relief surface 1118, an apex 1150, and a second protrusion
face 1154 that
extends from the apex 1150 and defines the gullet 1114. In the illustrated
embodiment, the apex
1150 is a pointed tip such that each protrusion 1130 is generally pointed,
rather than rounded.
The apexes 1150 define a plane 1158 that is spaced apart a distance R from a
plane 1134 defined
by tips 1106 of the cutting teeth 1050. In the illustrated embodiment, the
distance R is
approximately 0.034 inches. Furthermore, each apex 1150 is spaced apart a
distance 0 from the
tip 1106 of an adjacent cutting tooth 1050. In the illustrated embodiment, the
distance 0 is
approximately 0.07 inches. In such embodiments, a ratio between a distance N
from the
protrusion 1130 to the tip 1106 of one cutting tooth 1050 and the distance 0
is approximately
1.9. In other embodiments, the distances R, 0 may be relatively larger or
smaller, such as, for
example, 0.032 inches and 0.08 inches, respectively.
[0082] Figs. 14-15 illustrate a reciprocating saw blade 1230 according to
another
embodiment of the invention. The illustrated saw blade 1230 is similar to the
saw blade 30
described above with reference to Figs. 1-4, and similar parts have been given
the same reference
numbers, plus 1200.
[0083] The illustrated saw blade 1230 includes a body 1238, an attachment
portion 1242 for
coupling the blade 1230 to a reciprocating saw, a cutting portion 1246 having
a plurality of
cutting teeth 1250, and a plunge point 1254 for initiating a plunge cut. In
the illustrated
embodiment, the plunge point 1254 includes a leading tooth 1374, but not a
second tooth. The
leading tooth 1374 includes a tip 1382, a rake face 1386 extending from the
tip 1382 and at least
partially defining a leading gullet 1390, and a relief surface 1394 extending
from the tip 1382 to
an end 1398 of the body 1238. The rake face 1386 extends from the tip 1382 at
a leading rake
angle H relative to a plane 1334 defined by tips 1306 of the cutting teeth
1250. The leading rake
angle I-I, measured through the leading tooth 1374, is a negative rake angle
such that the leading
19
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
tooth 1374 is a negative rake tooth. In the illustrated embodiment, the
leading rake angle H is
approximately 95 to 105 degrees.
[0084] As shown in Fig. 15, the tip 1382 of the leading tooth 1374 is
spaced a distance U
from the tip 1306 of the nearest cutting tooth 1250. In the illustrated
embodiment, the distance U
is generally the same as a distance P (i.e., the pitch) between the tips 1306
of adjacent cutting
teeth 1250. As such, the leading gullet 1390 is generally the same size as
gullets 1314 defined
by the plurality of cutting teeth 1250.
[0085] Although not shown, in some embodiments, each of the cutting teeth
1250 may
include a protrusion that inhibits a nail from entering the gullet 1314 and
contacting a rake face
1310 of an adjacent cutting tooth 1250.
[0086] Figs. 16-17 illustrate a reciprocating saw blade 1430 according to
another
embodiment of the invention. The illustrated saw blade 1430 is similar to the
saw blade 30
described above with reference to Figs. 1-4, and similar parts have been given
the same reference
numbers, plus 1400.
[0087] The illustrated saw blade 1430 includes a body 1438, an attachment
portion 1442 for
coupling the blade 1430 to a reciprocating saw, a cutting portion 1446 having
a plurality of
cutting teeth 1450, and a plunge point 1454 for initiating a plunge cut. In
the illustrated
embodiment, the plunge point 1454 includes a leading tooth 1574, but not a
second tooth. The
leading tooth 1574 includes a tip 1582, a rake face 1586 extending from the
tip 1582 and at least
partially defining a leading gullet 1590, and a relief surface 1594 extending
from the tip 1582 to
an end 1598 of the body 1438. The rake face 1586 extends from the tip 1582 at
a leading rake
angle H relative to a plane 1534 defined by tips 1506 of the cutting teeth
1450. The leading rake
angle H, measured through the leading tooth 1574, is a positive rake angle
such that the leading
tooth 1574 is a positive rake tooth having substantially the same rake angle
as each of the cutting
teeth 1450. In the illustrated embodiment, the leading rake angle H is
approximately 80 to 88
degrees.
CA 02885473 2015-03-19
WO 21)11/133864 PCT/US2011/033583
[0088] The relief surface 1594 of the leading tooth 1574 extends from the
tip 1582 at a
leading relief angle I relative to the plane 1534. In the illustrated
embodiment, the leading relief
angle I is approximately 25 to 45 degrees.
[0089] As shown in Fig. 17, the tip 1582 of the leading tooth 1574 is
spaced a distance U
from the tip 1506 of the nearest cutting tooth 1450. The distance U is
generally greater than a
distance P (i.e., the pitch) between the tips 1506 of adjacent cutting teeth
1450. In the illustrated
embodiment, the distance U is approximately twice the distance P. As such, the
leading gullet
1590 is substantially larger than each gullet 1514 of the cutting teeth 1450.
[0090] Although not shown, in some embodiments, each of the cutting teeth
1450 may
include a protrusion that inhibits a nail from entering the gullet 1514 and
contacting a rake face
1510 of an adjacent cutting tooth 1450.
[00911 Figs. 18-19 illustrate a reciprocating saw blade 1630 according to
another
embodiment of the invention. The illustrated saw blade 1630 is similar to the
saw blade 30
described above with reference to Figs. 1-4, and similar parts have been given
the same reference
numbers, plus 1600.
[0092] The illustrated saw blade 1630 includes a body 1638, an attachment
portion 1642 for
coupling the blade 1630 to a reciprocating saw, a cutting portion 1646 having
a plurality of
cutting teeth 1650, and a plunge point 1654 for initiating a plunge cut. In
the illustrated
embodiment, the plunge point 1654 includes a leading tooth 1774, but not a
second tooth. The
leading tooth 1774 includes a tip 1782, a rake face 1786 extending from the
tip 1782 and at least
partially defining a leading gullet 1790, and a relief surface 1794 extending
from the tip 1782 to
an end 1798 of the body 1638. The rake face 1786 extends from the tip 1782 at
a leading rake
angle H relative to a plane 1734 defined by tips 1706 of the cutting teeth
1650. The leading rake
angle H, measured through the leading tooth 1774, is a positive rake angle
such that the leading
tooth 1774 is a positive rake tooth having substantially the same rake angle
as each of the cutting
teeth 1650. In the illustrated embodiment, the leading rake angle H is
approximately 80 to 88
degrees.
21
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
[0093] The relief surface 1794 of the leading tooth 1774 extends from the
tip 1782 at a
leading relief angle I relative to the plane 1734. In the illustrated
embodiment, the leading relief
angle I is approximately 25 to 45 degrees.
[0094] As shown in Fig. 19, the plunge point 1654 also includes a top edge
1802 extending
from the end 1798 of the body 1638 to a back portion 1774 of the body 1638.
The illustrated top
edge 1802 is an elongated edge that is oriented at an angle G relative to the
back portion 1774
such that the plunge point 1654 is a tapered plunge point. In some
embodiments, the angle G is
less than 15 degrees. In the illustrated embodiment, the angle G is
approximately 8 degrees. The
tapered plunge point 1654 improves plunge cut performance by reducing the
clearance required
for the saw blade 1630 to enter a work piece, thereby increasing cutting speed
and improving cut
accuracy and finish.
[0095] Although not shown, in some embodiments, each of the cutting teeth
1650 may
include a protrusion that inhibits a nail from entering a gullet 1714 and
contacting a rake face
1710 of an adjacent cutting tooth 1650.
100961 Figs. 20-21 illustrate a reciprocating saw blade 1830 according to
another
embodiment of the invention. The illustrated saw blade 1830 is similar to the
saw blade 30
described above with reference to Figs. 1-4, and similar parts have been given
the same reference
numbers, plus 1800.
[0097] The illustrated saw blade 1830 includes a body 1838, an attachment
portion 1842 for
coupling the blade 1830 to a reciprocating saw, a cutting portion 1846 having
a plurality of
cutting teeth 1850, and a plunge point 1854 for initiating a plunge cut. In
the illustrated
embodiment, the plunge point 1854 includes a leading tooth 1974, but not a
second tooth. The
leading tooth 1974 includes a tip 1982, a rake face 1986 extending from the
tip 1982 and at least
partially defining a leading gullet 1990, and a relief surface 1994 extending
from the tip 1982 to
an end 1998 of the body 1838. The rake face 1986 extends from the tip 1982 at
a leading rake
angle H relative to a plane 1934 defined by tips 1906 of the cutting teeth
1850. The leading rake
angle H, measured through the leading tooth 1974, is a negative rake angle
such that the leading
tooth 1974 is a negative rake tooth. In the illustrated embodiment, the
leading rake angle H is
approximately 95 to 105 degrees.
22
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
[0098] As shown in Fig. 21, the tip 1982 of the leading tooth 1974 is
spaced a distance U
from the tip 1906 of the nearest cutting tooth 1850. The distance U is
generally greater than a
distance P (i.e., the pitch) between the tips 1906 of adjacent cutting teeth
1850. In the illustrated
embodiment, the distance U is approximately twice the distance P. As such, the
leading gullet
1990 is substantially larger than each gullet 1914 of the cutting teeth 1850.
[0099] Although not shown, in some embodiments, each of the cutting teeth
1850 may
include a protrusion that inhibits a nail from entering the gullet 1914 and
contacting a rake face
1910 of an adjacent cutting tooth 1850.
[0100] Figs. 22-23 illustrate a reciprocating saw blade 2030 according to
another
embodiment of the invention. The illustrated saw blade 2030 is similar to the
saw blade 30
described above with reference to Figs. 1-4, and similar parts have been given
the same reference
numbers, plus 2000.
[0101] The illustrated saw blade 2030 includes a body 2038, an attachment
portion 2042 for
coupling the blade 2030 to a reciprocating saw, a cutting portion 2046 having
a plurality of
cutting teeth 2050, and a plunge point 2054 for initiating a plunge cut. In
the illustrated
embodiment, the plunge point 2054 includes a leading tooth 2174, but not a
second tooth. The
leading tooth 2174 includes a tip 2182, a rake face 2186 extending from the
tip 2182 and at least
partially defining a leading gullet 2190, and a relief surface 2194 extending
from the tip 2182 to
an end 2198 of the body 2038. The rake face 2186 extends from the tip 2182 at
a leading rake
angle H relative to a plane 2134 defined by tips 2106 of the cutting teeth
2050. The leading rake
angle H, measured through the leading tooth 2174, is a negative rake angle
such that the leading
tooth 2174 is a negative rake tooth. In the illustrated embodiment, the
leading rake angle H is
approximately 95 to 105 degrees.
[0102] As shown in Fig. 23, the tip 2182 of the leading tooth 2174 is
spaced a distance U
from the tip 2106 of the nearest cutting tooth 2050. The distance U is
generally greater than a
distance P (i.e., the pitch) between the tips 2106 of adjacent cutting teeth
2050. In the illustrated
embodiment, the distance U is approximately twice the distance P. As such, the
leading gullet
2190 is substantially larger than each gullet 2114 of the cutting teeth 2050.
23
CA 02885473 2015-03-19
WO 2011/133864 PCT/US2011/033583
10103] The plunge point 2054 also includes a top edge 2202 extending from
the end 2198 of
the body 2038 to a back portion 2074 of the body 2038. The illustrated top
edge 2202 is an
elongated edge that is oriented at an angle G relative to the back portion
2074 such that the
plunge point 2054 is a tapered plunge point. In some embodiments, the angle G
is less than 15
degrees. In the illustrated embodiment, the angle G is approximately 8
degrees.
[0104] Although not shown, in some embodiments, each of the cutting teeth
2050 may
include a protrusion that inhibits a nail from entering the gullet 2114 and
contacting a rake face
2110 of an adjacent cutting tooth 2050.
[0105] Figs. 24-25 illustrate a reciprocating saw blade 2230 according to
another
embodiment of the invention. The illustrated saw blade 2230 is similar to the
saw blade 30
described above with reference to Figs. 1-4, and similar parts have been given
the same reference
numbers, plus 2200.
[0106] The illustrated saw blade 2230 includes a body 2238, an attachment
portion 2242 for
coupling the blade 2230 to a reciprocating saw, a cutting portion 2246 having
a plurality of
cutting teeth 2250, and a plunge point 2254 for initiating a plunge cut. In
the illustrated
embodiment, the plunge point 2254 includes a leading tooth 2374, but not a
second tooth. The
leading tooth 2374 includes a tip 2382, a rake face 2386 extending from the
tip 2382 and at least
partially defining a leading gullet 2390, and a relief surface 2394 extending
from the tip 2382 to
an end 2398 of the body 2238. The rake face 2386 extends from the tip 2382 at
a leading rake
angle H relative to a plane 2334 defined by tips 2306 of the cutting teeth
2250. The leading rake
angle H, measured through the leading tooth 2374, is a negative rake angle
such that the leading
tooth 2374 is a negative rake tooth. In the illustrated embodiment, the
leading rake angle H is
approximately 95 to 105 degrees.
[0107] As shown in Fig. 25, the tip 2382 of the leading tooth 2374 is
spaced a distance U
from the tip 2306 of the nearest cutting tooth 2050. In the illustrated
embodiment, the distance U
is generally the same as a distance P (i.e., the pitch) between the tips 2306
of adjacent cutting
teeth 2050. As such, the leading gullet 2390 is generally the same size as
gullets 2314 defined
by the plurality of cutting teeth 2050.
24
CA 02 885473 2 015-03-1 9
WO 2011/133864 PCT/US2011/033583
[0108] The plunge point 2254 also includes a top edge 2402 extending from
the end 2398 of
the body 2238 to a back portion 2274 of the body 2238. The illustrated top
edge 2402 is an
elongated edge that is oriented at an angle G relative to the back portion
2274 such that the
plunge point 2254 is a tapered plunge point. In some embodiments, the angle G
is less than 15
degrees. In the illustrated embodiment, the angle G is approximately 8
degrees.
[0109] Although not shown, in some embodiments, each of the cutting teeth
2250 may
include a protrusion that inhibits a nail from entering the gullet 2314 and
contacting a rake face
2310 of an adjacent cutting tooth 2050.
[0110] Figs. 26-27 illustrate a reciprocating saw blade 2430 according to
another
embodiment of the invention. The illustrated saw blade 2430 is similar to the
saw blade 30
described above with reference to Figs. 1-4, and similar parts have been given
the same reference
numbers, plus 2400.
[0111] The illustrated saw blade 2430 includes a body 2438, an attachment
portion 2442 for
coupling the blade 2430 to a reciprocating saw, a cutting portion 2446 having
a plurality of
cutting teeth 2450, and a plunge point 2454 for initiating a plunge cut. The
plunge point 2454 is
similar to the plunge point 54 shown in Figs. 1-4 and includes a leading tooth
2574, a second
tooth 2578, and an enlarged leading gullet 2590. However, in the illustrated
embodiment, each
cutting tooth 2450 does not include a protrusion.
[0112] Although particular embodiments embodying independent aspects of the
present
invention have been shown and described, other alternative embodiments will
become apparent
to those skilled in the art and are within the intended scope of the
independent aspects of the
invention. For example, although the above saw blade tooth forms have been
described with
reference to saw blades for use with reciprocating saws that alternately move
the saw blades in
cutting directions and return directions, the tooth forms may be used on other
types of saw blades
having a linear edge, including band saw blades, hole saws, and jig saw
blades. In addition, the
tooth forms may additionally be used on saw blades having a curved edge,
including circular
saws blades.
[0113] Various features and advantages of the invention are set forth in
the following claims.
