Abstract:
A protector assembly includes a first shield segment defining a first blade space. The first shield segment includes a first channel structure defining a first channel facing the first blade space. The protector assembly further includes a second shield segment defining a second blade space. The second shield segment includes a second channel structure defining a second channel facing the second blade space. The first shield segment further includes (i) a first end portion that includes a first coupling structure, and (ii) a second end portion that includes a second coupling structure. The second shield segment further includes (i) a third end portion that includes a third coupling structure, and (ii) a fourth end portion that includes a fourth coupling structure. When the first end portion of the first shield segment is positioned adjacent to the third end portion of the second shield segment, the first coupling structure cooperates with the third coupling structure to couple the first end portion to the third end portion. When the second end portion of the first shield segment is positioned adjacent to the fourth end portion of the second shield segment, the second coupling structure cooperates with the fourth coupling structure to couple the second end portion to the fourth end portion.

Description:
FIELD 
     This patent relates generally to saw blade protectors, and particularly to protectors for circular saw blades. 
     BACKGROUND 
     Circular saw blades typically include a circular body portion and a cutting portion positioned at the peripheral edge of the body portion. Generally, a circular saw blade is configured to cut one or more particular materials. For example, a circular saw blade configured to cut building materials, such as wood and wood products, includes a cutting portion that has numerous cutting teeth. Whereas, a circular saw blade configured to cut masonry products, includes a toothless cutting portion that is coated with industrial diamonds. 
     The cutting portion of each type of circular saw blade may become damaged if the blade is dropped or otherwise mishandled. Accordingly, circular saw blades are frequently positioned within a saw blade protector in order to protect the cutting portion during transportation of the saw blade and also while the saw blade is displayed at the point of sale. 
     Currently available circular saw blade protectors work well to protect the cutting portion; however, further advancements are possible. For example, plastic “clam-shell” type saw blade protectors completely surround the body portion and the cutting portion of the saw blade. These types of protectors are often expensive to manufacture and are generally viewed as being difficult for the consumer to remove. Another type of currently available circular saw blade protector is referred to as a sleeve protector. The sleeve protector is an envelope made of plastic or stiff paper. A circular saw blade is generally easy to remove from the sleeve protector; however, the sleeve protector obscures the cutting portion from view of the consumer. Accordingly, it would be desirable to provide a circular saw blade protector that adequately protects the cutting portion, is comparatively inexpensive to manufacture, and allows inspection of the cutting portion at the point of sale. 
     SUMMARY 
     According to one embodiment of the present disclosure there is provided a protector assembly. The protector assembly includes a first shield segment defining a first blade space. The first shield segment includes a first channel structure defining a first channel facing the first blade space. The protector assembly further includes a second shield segment defining a second blade space. The second shield segment includes a second channel structure defining a second channel facing the second blade space. The first shield segment further includes (i) a first end portion that includes a first coupling structure, and (ii) a second end portion that includes a second coupling structure. The second shield segment further includes (i) a third end portion that includes a third coupling structure, and (ii) a fourth end portion that includes a fourth coupling structure. When the first end portion of the first shield segment is positioned adjacent to the third end portion of the second shield segment, the first coupling structure cooperates with the third coupling structure to couple the first end portion to the third end portion. When the second end portion of the first shield segment is positioned adjacent to the fourth end portion of the second shield segment, the second coupling structure cooperates with the fourth coupling structure to couple the second end portion to the fourth end portion. 
     According to another embodiment of the present disclosure there is provided a protector assembly. The protector assembly includes a first arcuate shield segment defining a first blade space, the first arcuate shield segment including a first arcuate channel structure defining a first arcuate channel facing the first blade space. The protector assembly further includes a second arcuate shield segment defining a second blade space, the second arcuate shield segment including a second arcuate channel structure defining a second arcuate channel facing the second blade space. The first arcuate shield segment includes (i) a first end portion that includes one of a first post and a first receptacle structure, and (ii) a second end portion that includes one of a second post and a second receptacle structure. The second shield segment includes (i) a third end portion that includes the other of the first post and the first receptacle structure, and (ii) a fourth end portion that includes the other of the second post and the second receptacle structure. When the first end portion of the first shield segment is positioned adjacent to the third end portion of the second shield segment, the first post and the first receptacle structure cooperate with each other to couple the first end portion to the third end portion. When the second end portion of the first shield segment is positioned adjacent to the fourth end portion of the second shield segment, the second post and the second receptacle structure cooperate with each other to couple the second end portion to the fourth end portion. 
     According to yet another embodiment of the present disclosure there is provided a protector assembly. The protector assembly includes a first shield segment defining a first blade space, the first shield segment including a first channel structure defining a first channel facing the first blade space. The protector assembly further includes a second shield segment defining a second blade space, the second shield segment including a second channel structure defining a second channel facing the second blade space. The first shield segment includes (i) a first end portion that includes a first coupling structure, and (ii) a second end portion. The second shield segment includes (i) a third end portion that includes a second coupling structure, and (ii) a fourth end portion that is attached to the second end portion. When the first end portion of the first shield segment is positioned adjacent to the third end portion of the second shield segment, the first coupling structure cooperates with the second coupling structure to couple the first end portion to the third end portion. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
       The above-described features and advantages, as well as others, should become more readily apparent to those of ordinary skill in the art by reference to the following detailed description and the accompanying figures in which: 
         FIG. 1  is a front elevational view of a circular saw blade and a circular saw blade protector; 
         FIG. 2  is a perspective view of an upper shield of the circular saw blade protector of  FIG. 1 , with the circular saw blade removed for clarity of viewing; 
         FIG. 3  is a rear elevational view of the upper shield of  FIG. 2 ; 
         FIG. 4  is a cross sectional view taken along the line IV-IV of  FIG. 3 , including a fragmentary view of a portion of the circular saw blade, which is also shown in cross section; 
         FIG. 5  is a perspective view of a lower shield of the circular saw blade protector of  FIG. 1 , with the circular saw blade removed for clarity of viewing; 
         FIG. 6  is a rear elevational view of the lower shield of  FIG. 5 ; 
         FIG. 7  is a cross sectional view taken along the line VII-VII of  FIG. 6 , including a fragmentary view of a portion of the circular saw blade, which is also shown in cross section; 
         FIG. 8  is a front elevational view of a circular saw blade and an alternative embodiment of the saw blade protector of  FIG. 1 ; 
         FIG. 9  is a front elevational view of a circular saw blade and yet another alternative embodiment of the saw blade protector of  FIG. 1 ; 
         FIG. 10  is a front elevational view of a circular saw blade and still another alternative embodiment of the circular saw blade protector of  FIG. 1 , with the circular saw blade protector shown in a closed position; and 
         FIG. 11  is a front elevational view of the saw blade protector of  FIG. 10  shown in an open position with the circular saw blade removed for clarity of viewing. 
     
    
    
     DETAILED DESCRIPTION 
     As shown in  FIG. 1 , a circular saw blade protector  100  for protecting a circular saw blade  104  includes an upper shield segment, shown as an upper shield  108 , and a lower shield segment, shown as a lower shield  112 . 
     In  FIGS. 2 and 3 , the upper shield  108  is shown apart from the lower shield  112  and with the saw blade  104  removed. The upper shield  108  includes a generally arc-shaped or arcuate structure, which is configured to extend for approximately 180° around the periphery of the saw blade  104 . The upper shield  108  is formed from a material, which transmits light, such as injection molded thermoplastic. The upper shield  108  is, therefore, transparent or translucent and a portion of the saw blade  104  is visible through the material of the upper shield. 
     The upper shield  108  includes a channel structure  116  and defines a blade space  120 . The channel structure  116  extends from a left end portion  124  of the upper shield  108  (shown on the right side of  FIGS. 1 and 2 ) to a right end portion  128  of the upper shield  108  (shown on the left side of  FIGS. 1 and 2 ). The channel structure  116  is generally arc-shaped and defines an upper channel  132 , which faces the blade space  120 . 
     As shown in  FIG. 4 , a cross section of the channel structure  116  shows the generally “U”-shaped upper channel  132 . The portion of the blade  104  positioned within the upper channel  132  is shown to the right of the broken line  138  and is referred to as a cutting portion  232  of the blade. The channel structure  116  surrounds the cutting portion  232 , but enables viewing of the cutting portion through the light-transmissive material of the channel structure. 
     As shown in  FIGS. 1-3 , the blade space  120  includes a semi-circle shaped area bounded by the channel structure  116  and the reference line  136 . An upper portion of a body  228  of the blade  104  (i.e. the portion of the blade  104 , which is positioned above the reference line  136 ) is positioned within the blade space  120 . 
     As shown in  FIG. 2 , the right end portion  128  of the upper shield  108  includes a coupling structure, shown as a post  140 , and the left end portion  124  of the upper shield includes another coupling structure, shown as a receptacle  144 . The post  140  is configured to cooperate with a right coupling structure of the lower shield  112 . The post  140  includes a shaft  148  terminated with a bulb  152 . As shown best in  FIG. 3 , the shaft  148  is spaced apart from the channel structure  116  to enable a cutting instrument, such as a pair of scissors, to access and cut the shaft. The bulb  152  has a width that is wider than that of the shaft  148 . 
     The receptacle  144  defines an opening  156  and a space  160  configured to receive at least a portion of a left connection structure of the lower shield  112 , thereby connecting the left end portion  124  to a portion of the lower shield  112 . 
     An image  164  of a pair of scissors and an arrow pointing toward the shaft  148  is formed into the right end portion  128 . The image  164  is a reference image, which identifies to the user of the saw blade  104  and saw blade protector  100  a region suitable for cutting to remove the saw blade protector from the blade (as explained below in detail). It is noted that, other embodiments of the upper shield  108  do not include the image  164 . 
     The upper shield  108  further includes a display structure  168  and a security sensor  172  attached to the display structure. The display structure  168  is made of the same light-transmissive material as the rest of the upper shield  108  and is configured to extend outwardly away from the channel structure  116 . The display structure  168  defines a field  176  in which the security sensor  172  is positioned. In an alternative embodiment, the display structure  168  includes a hanger opening (not shown) to receive a hanger unit (not shown) configured to support the blade  104  and the saw blade protector  100 . 
     The security sensor  172  is positioned in the field  176  defined by the display structure  168 . The security sensor  172  includes a radio frequency identification tag. In other embodiments, however, the security sensor  172  includes another type of security device. Also, in another embodiment, an adhesive label (not shown) is placed to cover the field  176  and the security sensor  172 , such that the security sensor remains functional, but not visible to the user. 
     As shown in  FIGS. 5 and 6 , the lower shield  112  includes a generally arc-shaped or arcuate structure, which is configured to extend for approximately 180° around the periphery of the saw blade  104 . The lower shield  112  is formed form the same light-transmissive material as the upper shield  108 . The lower shield  112  is, therefore, transparent or translucent and the cutting portion  232  of the saw blade  104  is visible through the material of the lower shield. 
     The lower shield  112  includes a channel structure  180  and defines a blade space  184 . The channel structure  180  extends from a left end portion  188  of the lower shield  112  (shown on the right side of  FIGS. 1 and 5 ) to a right end portion  192  of the lower shield (shown on the left side of  FIGS. 1 and 5 ). The channel structure  180  is generally arc-shaped and defines a lower channel  196 , which faces the blade space  184 . 
     As shown in  FIG. 7 , a cross section of the channel structure  180  shows the generally “U”-shaped lower channel  196 . The cutting portion  232  (to the right of broken line  138 ) of the blade  104  is positioned within the lower channel  196 . The channel structure  180  surrounds the cutting portion  232 , but enables viewing of the cutting portion through the material of the channel structure. 
     As shown in  FIGS. 1 ,  5 , and  6 , the blade space  184  includes a semi-circle shaped area bounded by the channel structure  180  and the reference line  136 . A lower portion of the body  228  of the blade  104  (that which is positioned below the reference line  136 ) is positioned within the blade space  184 . 
     As shown in  FIGS. 5 and 6 , the left end portion  188  of the lower shield  112  includes a coupling structure, shown as a post  200 , and the right end portion  192  of the lower shield includes another coupling structure, shown as a receptacle  204 . The post  200  includes a shaft  208  terminated with a bulb  212 . As shown best in  FIG. 6 , the shaft  148  is spaced apart from the channel structure  180  to enable a cutting instrument, such as a pair of scissors, to access and cut the shaft. The post  200  is configured to engage the receptacle  144  of the upper shield  108 . In particular, the bulb  212  passes through the opening  156  and into the space  160  to connect the left end portion  124  to the left end portion  188 . The bulb  212  has a width that is wider than that of the shaft  208 ; accordingly, after the bulb  212  passes through the opening  156 , the receptacle  144  retains the bulb within the space  160  and the shaft  208  extends through the opening  156 . 
     The receptacle  204  defines an opening  216  and a space  220  configured to receive and retain the bulb  152  of the post  140  of the upper shield  108 , thereby connecting the right end portion  128  to the right end portion  192 . When the right end portion  128  is connected to the right end portion  192 , the bulb  152  is positioned in the space  220  and the shaft  148  extends through the opening  216 . 
     As shown in  FIG. 1 , the lower shield  112  also includes an image  224  of a pair of scissors and an arrow pointing toward the shaft  208 . The image is formed into the left end portion  188 , and functions identically to the image  164 . 
     The saw blade  104  has a body  228 , a cutting portion  232 , and an arbor opening  236 . The body  228  includes a circular disk and the arbor opening  236  is positioned in the middle of the body. An upper portion of the body  228  is positioned in the blade space  120  of the upper shield  108  and a lower portion of the body is positioned in the blade space  184  of the lower shield  112 . The cutting portion  232  is positioned around the periphery of the body  228 . As shown in  FIG. 1 , the cutting portion  232  includes a plurality of cutting teeth  240 . In other embodiments of the blade  104 , the cutting portion  232  includes a different cutting portion, such as a cutting surface that includes industrial diamonds or carbide tipped cutting teeth. 
     In operation, the circular saw blade protector  100  is configured to protect the circular saw blade  104  during transportation of the blade and during display of the blade at the point of sale, among other times and locations. At the point of sale, a hanger unit (not shown) is inserted through the arbor opening  236  to support the blade  104  and the saw blade protector  100 . The saw blade protector  100  prevents the cutting portion  232  from being damaged due to mishandling of the saw blade  104 . Specifically, the material of the upper shield  108  and the lower shield  112  absorbs shock and resists deformation, thereby preventing damage to the cutting portion  232 . 
     The saw blade protector  100  enables the cutting portion  232  of the blade  104  to be visible through the material of the upper shield  108  and the lower shield  112 . Accordingly, a potential purchaser of the blade  104  is able to inspect the configuration and construction of the cutting portion  232  without having to the remove the blade  104  from the saw blade protector  100 . Also, the security sensor  172  remains associated with the blade  104  during the potential purchaser&#39;s inspection of the blade. The potential purchaser is also referred to as a user. 
     To associate the saw blade protector  100  with the blade  104 , first a lower portion of the cutting portion  232  is inserted into the lower channel  196  defined by the lower shield  112 . Second, an upper portion of the cutting portion  232  is inserted into the upper channel  132  defined by the upper shield  108 . Next, the left end portion  124  is moved toward the left end portion  188  and the right end portion  128  is moved toward the right end portion  192 . 
     When the left end portion  124  is positioned adjacent to the left end portion  188 , the bulb  212  of the post  200  is aligned with the opening  156  of the receptacle  144 . Continued movement of the left end portion  124  toward the left end portion  188  causes the bulb  212  to pass through the opening  156  and to enter and be retained within the space  160 . The shape of the bulb  212  prevents the bulb from being withdrawn from the space  160  through the opening  156 . Therefore, when the post  200  is received by the receptacle  144 , the left end portion  124  is “permanently” connected to the left end portion  188 , as shown in  FIG. 1 . A “permanent” connection means that the left end portion  124  cannot be separated from the left end portion  188  without destroying one or more of the post  200  and the receptacle  144 . 
     Similarly, when the right end portion  128  is positioned adjacent to the right end portion  192 , the bulb  152  of the post  140  is aligned with the opening  216  of the receptacle  204 . Continued movement of the right end portion  128  toward the right end portion  192  causes the bulb  152  to pass through the opening  216  and to enter and be retained within the space  220 . The shape of the bulb  152  prevents the bulb from being withdrawn from the space  220  through the opening  216 . Therefore, when the post  140  is received by the receptacle  204 , the right end portion  128  is “permanently” connected to the right end portion  192 , as shown in  FIG. 1 . Also, the upper blade space  120  and the lower blade space  184  are interposed between the upper channel structure  116  and the lower channel structure  180 . 
     After the upper shield  108  is connected to the lower shield  112 , the upper shield cannot be separated from the lower shield without destroying at least a portion of one or more of the post  140 , the post  200 , the receptacle  144 , the receptacle  204 , the channel structure  116 , and the channel structure  180 . The non-separable nature of the saw blade protector  100  helps to ensure that the security sensor  172  remains associated with the blade  104  until blade is purchased. The non-separable nature of the saw blade protector  100  also helps to ensure that the cutting portion  232  of the blade  104  remains protected until the blade is purchased and the saw blade protector  100  is removed. 
     To disassociate the saw blade protector  100  from the saw blade  104 , the shaft  148  of the post  140  and/or the shaft  208  of the post  200  are cut. As shown in  FIG. 1 , when the upper shield  108  is connected to the lower shield  112 , the left end portion  124  is positioned apart from the left end portion  188  by the distance represented by the reference line  244 . The shaft  208  is exposed in this region and is easily cut with a pair of scissors or a knife. The arrow of the image  224  points to this portion of the shaft  208 , thereby signaling to the user the preferred location in which to cut the saw blade protector  100  when removing the saw blade protector from the blade  104 . After the shaft  208  is cut, the upper shield  108  and the lower shield  112  are bent and moved to enable the blade  104  to be removed from the saw blade protector  100 . To further simplify the disassociation of the blade  104  from the saw blade protector  100 , however, the shaft  148  is cut in a similar manner to enable separation of the upper shield  108  from the lower shield  112 . 
     As shown in  FIG. 8 , another embodiment of a saw blade protector  100 ′ is disclosed. The saw blade protector  100 ′ includes the same components, functions the same way, and is used with the same blade  104 ′ as the saw blade protector  100 , except that the saw blade protector  100 ′ includes a display structure  168 ′, which extends downwardly toward the lower shield  112 ′. The display structure  168 ′ is otherwise the same as the display structure  168  of the upper shield  108 . 
     As shown in  FIG. 9 , yet another embodiment of a saw blade protector  100 ″ is disclosed. The saw blade protector  100 ″ includes the same components, functions the same way, and is used with the same blade  104 ″ as the saw blade protector  100 , except that the upper shield  108 ″ does not include the display structure  168 . Accordingly, the upper shield  108 ″ and the lower shield  112 ″ are identical to one another. Specifically, in  FIG. 9 , the upper shield  108 ″ is positioned in a first orientation, and the lower shield  112 ″ is another of the upper shield  108 ″ that is in a horizontally inverted position. The identical nature of the upper shield  108 ″ and the lower shield  112 ″ simplifies the manufacturing and assembly of the saw blade protector  100 ″. 
     As shown in  FIGS. 10 and 11 , still another embodiment of a circular saw blade protector  100 ′″ is disclosed. Components of the saw blade protector  100 ′″ that are identical or are substantially the same as the components of the saw blade protector  100  include like reference numerals terminated with three prime symbols (′″). Unlike the saw blade protector  100  shown in  FIGS. 1-7 , which includes the upper shield  108  that is completely separable from the lower shield  112 , the saw blade protector  100 ′″ includes an upper shield  108 ′″ and a lower shield  112 ′″, which are integrally formed together as a single monolithic part. Specifically, the left end portion  124 ′″ of the upper shield  112 ′″ is attached to the left end portion  188 ′″ of the lower shield  112 ′″. 
     The saw blade protector  100 ′″ is formed from a resilient and light-transmissive material. The resiliency of the saw blade protector  100 ′″ enables the saw blade protector to return to the shape as shown in  FIG. 10  after being bent, twisted, or otherwise deformed. Note, however, that the material of the saw blade protector  100 ′″ also enables the saw blade protector to prevent the cutting portion  232 ′″ from being damaged due to mishandling of the saw blade  104 ′″. Specifically, the material of the saw blade protector  100 ′″ absorbs shock and resists deformation, thereby preventing damage to the cutting portion  232 ′″. 
     The light-transmissive nature of the saw blade protector  100 ′″ enables the cutting portion  232 ′″ of the saw blade  104 ′″ to be visible through the material of the saw blade protector. An exemplary material for forming the saw blade protector  100 ′″ includes injection molded thermoplastic. Since the upper shield  108 ′ and the lower shield  112 ′ are a single part, the entire saw blade protector  100 ′″ may be formed in a “one-shot” injection molding process. 
     To associate the saw blade protector  100 ′″ with the circular saw blade  104 ′″, first the right end portion  192 ′″ is moved away from the right end portion  128 ′″ to position the saw blade protector approximately as shown in  FIG. 11 . The position of the saw blade protector  100 ′″ in  FIG. 11  approximately resembles a horizontally-inverted “C” shape. Next, the upper portion of the saw blade  104 ′″ is positioned in the upper channel  132 ′″ defined by the upper shield  108 ′″. Thereafter, the right end portion  192 ′″ is moved toward the right end portion  128 ′″, which causes the lower portion of the saw blade  104 ′″ to be positioned in the lower channel  196 ′″ in the lower shield  112 ′″. 
     When the right end portion  128 ′″ is positioned adjacent to the right end portion  192 ′″, the bulb  152 ′″ of the post  140 ′″ is aligned with the opening  216 ′″ of the receptacle  204 ′″. Continued movement of the right end portion  128 ′″ toward the right end portion  192 ′″ causes the bulb  152 ′″ to pass through the opening  216 ′″ and to enter and be retained within the space  220 ′″. The shape of the bulb  152 ′″ prevents the bulb from being withdrawn from the space  220 ′″ through the opening  216 ′″. Therefore, when the post  140 ′″ is received by the receptacle  204 ′″, the right end portion  128 ′″ is “permanently” connected to the right end portion  192 ′″, as shown in  FIG. 10 . 
     To disassociate the saw blade protector  100 ′″ from the circular saw blade  104 ′″ the shaft  148 ′″ of the post  140 ′″ is cut. After the shaft  148 ′″ is cut, the upper shield  108 ′″ and the lower shield  112 ′″ are bent and moved to approximately the position shown in  FIG. 10  to enable the blade  104 ′″ to be removed from the saw blade protector  100 ′″. 
     Although not illustrated in  FIGS. 10 and 11 , in some embodiments of the circular saw blade protector  104 ′ the left end portion  124 ′ and the left end portion  188 ′″ are removably attached together. In this embodiment of the saw blade protector  104 ′, the left end portion  124 ′″ includes a coupling structure (not shown) and the left end portion  188 ′″ includes a coupling structure (not shown). The coupling structure of the left end portion  124 ′″ is configured to removably receive the coupling structure of the left end portion  188 ′″. 
     It is noted that while the coupling structures in each of the circular saw blade protectors  100 ,  100 ′,  100 ″,  100 ′″ have been shown as posts  140 ,  140 ′,  140 ″,  140 ′″ and receptacles  204 ,  204 ′,  204 ″,  204 ′″, in other embodiments of the circular saw blade protector the coupling structures are any elements configured to be “permanently” attached to each other. 
     While the saw blade protector  100 ,  100 ′,  100 ″,  100 ′″ has been illustrated and described in detail in the figures and the foregoing description, the same should be considered as illustrative and not restrictive in character. It should be understood that only the preferred embodiments have been presented and that all changes, modifications, and further application that come within the spirit of the disclosure are desired to be protected.