Variable tooth saw blade

• US 7,225,715 B2
• Filed: 05/13/2004
• Issued: 06/05/2007
• Est. Priority Date: 03/19/2002
• Status: Expired due to Fees

• Current Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Original Assignee: Black & Decker Incorporated (Stanley Black & Decker, Inc.)
• Inventors: Lowder, Jeremy A., Vilagi, Scott A.
• Primary Examiner(s): Dexter; Clark F.
• Application Number:
  US10/845,284
• Publication Number:
  US 20050109185A1
• Time in Patent Office: 1,118 Days
• Field of Search: 836/61, 836/76, 838/35, 838/36, 838/39, 83846-855
• US Class Current: 83/848
• CPC Class Codes: B23D 61/021 Types of set; Variable teeth, e.g. variable in height or gullet depth; Varying pitch; Details of gullet
• CPC Class Codes: Y02P 70/10 Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working
• CPC Class Codes: Y10T 83/9319 Toothed blade or tooth therefor
• CPC Class Codes: Y10T 83/9346 Uniformly varying teeth or tooth spacing
• CPC Class Codes: Y10T 83/935 Plural tooth groups
• CPC Class Codes: Y10T 83/9367 Teeth having cutting edge perpendicular to blade surface
• CPC Class Codes: Y10T 83/9403 Disc type

Abstract

An apparatus for cutting materials and more specifically an improved saw blade includes a plurality of variable teeth thereon. The variable tooth saw blade cuts faster and smoother while reducing harmonic vibrations. Specifically, the teeth on the saw blade are grouped into sections with differing circumferential widths and differing spacing between the sections.

Claims

1. A saw blade comprising:

a flat, circular disc having a peripheral outer edge and a center hole;

a plurality of circumferentially-spaced teeth each having a substantially axially extending cutting edge and projecting radially outwardly from the peripheral outer edge;

a first group of the cutting edges defining a first circumferential width between each adjacent pair of the cutting edges in the first group;

a second group of the cutting edges defining a second circumferential width between each adjacent pair of the cutting edges in the second group;

the second circumferential width differing from the first circumferential width; and

a third group of cutting edges defining a third circumferential width as the distance between adjacent the cutting edges in the third group;

at least one of the first, second and third groups including at least three of the cutting edges; and

the third circumferential width differing from the first and second circumferential widths.

2. The saw blade of claim 1 wherein the first group includes five cutting edges, the second group includes three cutting edges, and the third group includes two cutting edges.

3. The saw blade of claim 2 wherein the disc is divided into a first half and a second half with the first, second and third groups of cutting edges all being within the first half and defined as a first set, and the second half including a second set that is a copy exact of the first set positioned in a diametrically opposite manner.

4. The saw blade of claim 2 wherein the first group includes a first cutting edge and a last cutting edge defining therebetween a first group circumferential width of approximately fifty-six degrees;

the second group includes a first cutting edge and a last cutting edge defining therebetween a second group circumferential width of approximately forty degrees; and

the third group includes a first cutting edge and a last cutting edge defining therebetween a third group circumferential width of approximately twenty-five degrees.

5. The saw blade of claim 4 wherein the disc is divided into a first half and a second half with the first, second and third groups of cutting edges all being within the first half and defined as a first set, and the second half including a second set that is a copy exact of the first set positioned in a diametrically opposite manner.

6. The saw blade of claim 5 wherein at least three circumferential spaces are provided respectively between at least three of the first and second groups, the second and third groups, and the third and first groups, and wherein a first circumferential space is of approximately a fourteen-degree circumferential width, a second circumferential space is of approximately a twenty-degree circumferential width and a third circumferential space is of approximately a twenty-five-degree circumferential width.

7. The saw blade of claim 2 wherein the first group includes a first cutting edge and a last cutting edge defining therebetween a first group circumferential width ranging from fifty-four degrees to fifty-eight degrees, inclusive;

the second group includes a first cutting edge and a last cutting edge defining therebetween a second group circumferential width ranging from thirty-eight degrees to forty-two degrees, inclusive; and

the third group includes a first cutting edge and a last cutting edge defining therebetween a third group circumferential width ranging from twenty-three degrees to twenty-seven degrees, inclusive.

8. The saw blade of claim 7 wherein the disc is divided into a first half and a second half with the first, second and third groups of cutting edges all being within the first half and defined as a first set, and the second half including a second set that is a copy exact of the first set positioned in a diametrically opposite manner.

9. The saw blade of claim 8 wherein at least three circumferential spaces are provided respectively between at least three of the first and second groups, the second and third groups, and the third and first groups, and wherein the circumferential spaces include a first circumferential space having a circumferential width ranging from twelve degrees to sixteen degrees, inclusive, a second circumferential space having a circumferential width ranging from eighteen degrees to twenty-two degrees, inclusive, and a third circumferential space having a circumferential width ranging from twenty-three degrees to twenty-seven degrees, inclusive.

10. The saw blade of claim 2 wherein the first group includes a first cutting edge and a last cutting edge defining therebetween a first group circumferential width ranging from fifty-four degrees to fifty-eight degrees, inclusive.

11. The saw blade of claim 10 wherein the second group includes a first cutting edge and a last cutting edge defining therebetween a second group circumferential width ranging from thirty-eight degrees to forty-two degrees, inclusive.

12. The saw blade of claim 11 wherein a first circumferential space is provided between the first and second groups and has a circumferential width ranging from twelve degrees to sixteen degrees, inclusive.

13. The saw blade of claim 12 wherein the third group includes a first cutting edge and a last cutting edge defining therebetween a third group circumferential width ranging from twenty-three degrees to twenty-seven degrees, inclusive.

14. The saw blade of claim 13 wherein a second circumferential space is provided between the second and third groups and has a circumferential width ranging from eighteen degrees to twenty-two degrees, inclusive.

15. The saw blade of claim 10 wherein the third group includes a first cutting edge and a last cutting edge defining therebetween a third group circumferential width ranging from twenty-three degrees to twenty-seven degrees, inclusive.

16. The saw blade of claim 1 wherein a first circumferential space is provided between the first and second groups.

17. The saw blade of claim 16 wherein the first circumferential space extends between adjacent cutting edges such that there are no cutting edges within the first circumferential space.

18. The saw blade of claim 17 wherein a second circumferential space is provided between the second and third groups.

19. The saw blade of claim 18 wherein the second circumferential space extends between adjacent cutting edges such that there are no cutting edges within the second circumferential space.

20. The saw blade of claim 19 wherein the disc is divided into a first half and a second half with the first, second and third groups of cutting edges all being within the first half.

21. The saw blade of claim 20 further including a fourth group of the cutting edges which is within the second half of the disc and defines a fourth circumferential width as the distance between adjacent cutting edges in the fourth group;

wherein the fourth circumferential width is the same as the first circumferential width; and

wherein a third circumferential space is provided between the third and fourth groups.

22. The saw blade of claim 21 wherein the third circumferential space extends between adjacent cutting edges such that there are no cutting edges within the third circumferential space.

23. The saw blade of claim 22 further including a fifth group of the cutting edges which is within the second half of the disc and defines a fifth circumferential width as the distance between adjacent cutting edges in the fifth group;

wherein the fifth circumferential width is the same as the second circumferential width; and

wherein a fourth circumferential space is provided between the fourth and fifth groups.

24. The saw blade of claim 23 wherein the fourth circumferential space extends between adjacent cutting edges such that there are no cutting edges within the fourth circumferential space.

25. The saw blade of claim 24 further including a sixth group of the cutting edges which is within the second half of the disc and defines a sixth circumferential width as the distance between adjacent cutting edges in the sixth group;

wherein the sixth circumferential width is the same as the third circumferential width; and

wherein a fifth circumferential space is provided between the fifth and sixth groups.

26. The saw blade of claim 25 wherein the fifth circumferential space extends between adjacent cutting edges such that there are no cutting edges within the fifth circumferential space.

27. The saw blade of claim 26 wherein a sixth circumferential space is provided between the sixth and first groups.

28. The saw blade of claim 27 wherein the sixth circumferential space extends between adjacent cutting edges such that there are no cutting edges within the sixth circumferential space.

29. The saw blade of claim 1 further comprising a fourth group of the cutting edges defining a fourth circumferential width between each adjacent pair of the cutting edges in the fourth group;

the fourth circumferential width differing from the first, second and third circumferential widths.

30. The saw blade of claim 29 wherein the first group includes nine cutting edges, the second group includes seven cutting edges, the third group includes five cutting edges, and the fourth group includes four cutting edges.

31. The saw blade of claim 30 wherein the disc is divided into a first half and a second half with the first, second, third and fourth groups of the cutting edges all being within the first half and defined as a first set, and the second half including a second set that is an exact copy of the first set positioned in a diametrically opposite manner.

32. The saw blade of claim 30 wherein the first group includes a first cutting edge and a last cutting edge defining therebetween a first group circumferential width of approximately thirty-six degrees;

the second group includes a first cutting edge and a last cutting edge defining therebetween a second group circumferential width of approximately thirty-six degrees;

the third group includes a first cutting edge and a last cutting edge defining therebetween a third group circumferential width of approximately thirty-six degrees; and

the fourth group includes a first cutting edge and a last cutting edge defining therebetween a fourth group circumferential width of approximately forty-five degrees.

33. The saw blade of claim 32 wherein the disc is divided into a first half and a second half with the first, second, third and fourth groups of the cutting edges all being within the first half and defined as a first set, and the second half including a second set that is an exact copy of the first set positioned in a diametrically opposite manner.

34. The saw blade of claim 33 wherein between the first and second groups in both sets there is a first circumferential space of an approximately four-and-a-half-degree circumferential width;

between the second and third groups in both sets there is a second circumferential space of an approximately six-degree circumferential width;

between the third and fourth groups in both sets there is a third circumferential space of an approximately nine-degree circumferential width; and

between the fourth group in each set and the first group in the respective other set there is a fourth circumferential space of an approximately seven-and-a-half-degree circumferential width.

35. The saw blade of claim 30 wherein the first group includes a first cutting edge and a last cutting edge defining therebetween a first group circumferential width ranging from thirty-four degrees to thirty-eight degrees, inclusive;

the second group includes a first cutting edge and a last cutting edge defining therebetween a second group circumferential width ranging from thirty-four degrees to thirty-eight degrees, inclusive;

the third group includes a first cutting edge and a last cutting edge defining therebetween a third group circumferential width ranging from thirty-four degrees to thirty-eight degrees; and

the fourth group includes a first cutting edge and a last cutting edge defining therebetween a fourth group circumferential width ranging from forty-three degrees to forty-seven degrees, inclusive.

36. The saw blade of claim 35 wherein the disc is divided into a first half and a second half with the first, second, third and fourth groups of the cutting edges all being within the first half and defined as a first set, and the second half including a second set that is an exact copy of the first set positioned in a diametrically opposite manner.

37. The saw blade of claim 36 wherein between the first and second groups in both sets there is a first circumferential space having a circumferential width ranging from two-and-a-half degrees to six-and-a-half degrees;

between the second and third groups in both set there is a second circumferential space having a circumferential width ranging from four degrees to eight degrees;

between the third and fourth groups in both sets there is a third circumferential space having a circumferential width ranging from seven degrees to eleven degrees; and

between the fourth group in each set and the first group in the respective other set there is a fourth circumferential space having a circumferential width ranging from five-and-a-half to nine-and-a-half degrees, inclusive.

38. The saw blade of claim 29 wherein the first group includes twelve cutting edges, the second group includes eight cutting edges, the third group includes twelve cutting edges, and the fourth group includes three cutting edges.

39. The saw blade of claim 38 wherein the disc is divided into a first half and a second half with the first, second, third and fourth groups of the cutting edges all being within the first half and defined as a first set, and the second half including a second set that is an exact copy of the first set positioned in a diametrically opposite manner.

40. The saw blade of claim 38 wherein the first group includes a first cutting edge and a last cutting edge defining therebetween a first group circumferential width of approximately thirty-eight-and-a-half degrees;

the second group includes a first cutting edge and a last cutting edge defining therebetween a second group circumferential width of approximately thirty-two-and-a-half degrees;

the third group includes a first cutting edge and a last cutting edge defining therebetween a third group circumferential width of approximately sixty-six degrees; and

the fourth group includes a first cutting edge and a last cutting edge defining therebetween a fourth group circumferential width of approximately twenty-one-and-a-half degrees.

41. The saw blade of claim 40 wherein the disc is divided into a first half and a second half with the first, second, third and fourth groups of the cutting edges all being within the first half and defined as a first set, and the second half including a second set that is an exact copy of the first set positioned in a diametrically opposite manner.

42. The saw blade of claim 41 wherein between the first and second groups in both sets there is a first circumferential space of an approximately three-and-a-half-degree circumferential width;

between the second and third groups in both sets there is a second circumferential space of an approximately four-and-a-half-degree circumferential width;

between the third and fourth groups in both sets there is a third circumferential space of an approximately six-degree circumferential width; and

between the fourth group in each set and the first group in the respective other set there is a fourth circumferential space of an approximately seven-and-a-half-degree circumferential width.

43. The saw blade of claim 38 wherein the first group includes a first cutting edge and a last cutting edge defining therebetween a first group circumferential width ranging from thirty-six-and-a-half degrees to forth-and-a-half degrees, inclusive;

the second group includes a first cutting edge and a last cutting edge defining therebetween a second group circumferential width ranging from thirty-and-a-half to thirty-four-and-a-half degrees, inclusive;

the third group includes a first cutting edge and a last cutting edge defining therebetween a third group circumferential width ranging from sixty-four degrees to sixty-eight degrees, inclusive; and

the fourth group includes a first cutting edge and a last cutting edge defining therebetween a fourth group circumferential width ranging from nineteen-and-a-half degrees to twenty-three-and-a-half degrees, inclusive.

44. The saw blade of claim 43 wherein the disc is divided into a first half and a second half with the first, second, third and fourth groups of the cutting edges all being within the first half and defined as a first set, and the second half including a second set that is an exact copy of the first set positioned in a diametrically opposite manner.

45. The saw blade of claim 44 wherein between the first and second groups in both sets there is a first circumferential space having a circumferential width ranging from one-and-a-half degrees to five-and-a-half degrees, inclusive;

between the second and third groups in both sets there is a second circumferential space having a circumferential width ranging from two-and-a-half degrees to six-and-a-half degrees, inclusive;

between the third and fourth groups in both sets there is a third circumferential space having a circumferential width ranging from four degrees to eight degrees, inclusive; and

between the fourth group in each set and the first group in the respective other set there is a fourth circumferential space having a circumferential width ranging from five-and-a-half degrees to nine-and-a-half degrees, inclusive.

46. A saw blade comprising:

a flat, circular disc having a peripheral outer edge and a center hole, the disc being divided into a first half and a second half, each half being a copy exact of the other half positioned in a diametrically opposite manner;

a plurality of circumferentially-spaced teeth each having a substantially axially extending cutting edge and projecting radially outwardly from the peripheral outer edge;

a first group of the cutting edges in each half having five cutting edges including a first cutting edge and a last cutting edge defining therebetween a first group circumferential width of approximately fifty-six degrees;

a second group of the cutting edges in each half having three cutting edges including a first cutting edge and a last cutting edge defining therebetween a second group circumferential width of approximately forty degrees;

a third group of the cutting edges in each half having two cutting edges including a first cutting edge and a last cutting edge defining therebetween a third group circumferential width of approximately twenty-five degrees;

a first circumferential space being between the first and second groups in each half and having an approximately fourteen-degree circumferential width;

a second circumferential space being between the second and third groups in each half and having an approximately twenty-degree circumferential width; and

a third circumferential space being between the third group in each half and the first group in the respective other half and having an approximately twenty-five-degree circumferential width.