Straight cutting oscillating blade

An accessory tool for an oscillating power tool includes a blade portion including a first lateral edge portion, a second lateral edge portion, and a leading edge portion, the leading edge portion defining a cutting edge. A reinforcement structure extends linearly across the blade portion from a first position located on the leading edge portion proximate the first lateral edge portion to a second position located on the second lateral edge portion and spaced apart from the leading edge portion. The reinforcement structure defines a cutting zone that encompasses a leading region of the blade portion between the reinforcement structure and the leading edge portion, the reinforcement structure being configured to increase a stiffness of the blade portion.

TECHNICAL FIELD

This disclosure relates generally to power tools, and, more particularly, to oscillating tools for straight cutting.

BACKGROUND

In general, oscillating tools are light-weight, handheld power tools capable of being equipped with a variety of tool accessories and attachments, such as cutting blades, sanding discs, grinding tools, and many others. These types of tools, referred to hereinafter as power tools, typically include a generally cylindrically-shaped main body that serves as an enclosure for an electric motor as well as a hand grip for the tool. The electric motor is operably coupled to a drive member, referred to herein as a tool mount, that extends from a portion of the main body of the power tool. The electric motor is configured to rotate and/or oscillate the tool mount at relatively high frequencies.

The tool mount in turn is configured to secure different attachments so that as the tool mount is driven to move by the electric motor, an accessory tool secured to the mount is driven to perform work on a workpiece. Attachments usable with an oscillating tool include saw blades, sanders, raspers, grinders, scrapers, cutters, and polishers. Attachments can generally be mounted in a variety of orientations, which enables precision working in otherwise hard to reach areas.

Straight blades including cutting teeth on an end side have been used as saw blade attachments for making plunge cuts, whereby the straight blade descends into a material being cut rather than moving transversely along a straight cut. Typically, oscillating blades used for straight cuts tend to flex during cutting, which can distort an otherwise straight cut, damage the blade, or damage the material being cut. Straight blades have been proposed that have an increased blade thickness to decrease flexing and improve straight cut performance. However, increasing blade thickness increases a mass of the oscillating tool and a vibration caused by the oscillating tool when in use, and can have other detrimental effects. What is needed, therefore, is a straight blade for an oscillating tool optimized for straight cuts.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of the embodiments described herein, reference is now made to the drawings and descriptions in the following written specification. No limitation to the scope of the subject matter is intended by the references. This disclosure also includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the described embodiments as would normally occur to one skilled in the art to which this document pertains.

FIG. 1depicts a plan view of an embodiment of a straight cutting oscillating blade100having an attachment portion102, and a blade portion104. The attachment portion102can be configured in a known manner to attach the blade100to an oscillating tool (FIG. 4) such that the blade100can be oscillated by the tool. The blade portion104includes lateral edges120,122and a leading edge124. The lateral edges120,122extend forwardly from the attachment portion102, and the leading edge124extends between the distal ends of the lateral edges120,122. The leading edge124defines a cutting edge and may include cutting teeth configured to perform an operation on a workpiece, such as a straight cut. The blade100may also include a transition portion118that offsets the blade portion104of the blade from the attachment portion102.

The blade100further includes a reinforcement structure108that extends across the blade portion104and defines a cutting zone106that encompasses the blade portion from the reinforcement structure to a leading edge portion116. The reinforcement structure is configured to increase a stiffness of the blade100, without increasing the thickness of the cutting zone106or increasing the inertial mass of the blade100. In the embodiment illustrated inFIG. 1, the cutting zone106has a substantially triangular shape, although cutting zones having other shapes are also contemplated. The reinforcement structure108extends from a corner110of the leading edge124and at least substantially across the blade100at an angle relative to the leading edge124. As can be seen inFIG. 2, the reinforcement structure108extends to a position on the lateral edge that is proximate the transition portion118. In some embodiments, the cutting zone106is defined at least in part by the reinforcement structure108.

The reinforcement108as illustrated inFIG. 1may be a separate reinforcement member that has been suitably attached to the blade100. Alternatively, the reinforcement may be a stamped or formed geometry in the blade100. The reinforcement108may advantageously extend across an entire width of the blade100, so that the reinforcement108may be formed by a uniform stamping operation across the blade100. The reinforcement108is further configured to limit walking or flexing of the blade100during straight cutting. Due to inclusion of the reinforcement108, the cutting zone can be configured with a thinner profile than a conventional blade, resulting in a lower mass and less vibration, and more accurate cutting with less distortion. In an example, the cutting zone106has a thickness that is 25% thinner or more, relative to a conventional straight blade for an oscillating tool.

As illustrated inFIG. 1, the blade100has a substantially rectilinear shape. In a non-limiting example, the width of the blade100can be from about 0.5 inches to about 4 inches, or more particularly, about 1.5 inches. A length of the blade100can be from about 2 inches to about 10 inches, or more particularly, about 5 inches. The cutting zone106can have a first thickness that is thinner than at least one of a thickness of the reinforcement108or a thickness of another region of the blade100beyond the reinforcement108. In an example, the cutting zone106can have a thickness of about 0.05 inches or less for a blade formed of stainless steel. Portions of the blade100proximate to the attachment portion may be rounded, beveled, or cut away for advantageous handling and attachment of the blade100to an oscillating tool.

The blade100can be made using, for example, stainless steel, tungsten carbide, brass, cobalt, or any other suitable materials. In an embodiment, the cutting teeth of the cutting edge may include at least one different material, such as diamond, or carbide. In an embodiment, the blade100is made using a first material than is different from a second material used to make the reinforcement108. For example, the blade100can be made using stainless steel, and the reinforcement can be made using iron, plastics, carbon fiber, rubber, etc., or combinations thereof.

FIG. 2depicts a plan view of another embodiment of a straight cutting oscillating blade200having an attachment portion202, a blade portion204, a cutting zone206and a reinforcement208. In this embodiment, the blade200further includes a cutout region210located between the attachment portion202and the reinforcement208such that the reinforcement208is located between the cutting zone206and the cutout region210. The cutout region210is configured to reduce the mass of the blade200and to lessen vibration of an oscillating tool driving the blade200.

As illustrated inFIG. 2, the cutout region210has a first side212that is substantially parallel to the reinforcement208and a second side214that is substantially perpendicular to the first side212. However, in other embodiments, cutout regions with other shapes are also contemplated. In an example, a cutout region is defined by at least one curved or beveled side. In another example, a first radius connects the first side212to the straight cutting oscillating blade200, and a second radius connects the second side214to the straight cutting oscillating blade200. The cutout region210may be formed with other elements of the blade200, such as in a common stamping operation.

FIG. 3depicts an exemplary image of a blade that demonstrates a cutting zone for a straight cut with a straight cutting oscillating blade.

FIGS. 4-5depict images of exemplary embodiments of oscillating tools with a straight cutting oscillating blade mounted thereon in conjunction with a workpiece upon which a straight cut has been performed using the oscillating tool. As can be seen inFIGS. 4 and 5, the oscillating tool500includes a portable housing502. A motor (not visible) is enclosed within the housing502. The motor is configured to oscillate a tool holder504that is located exterior to the housing. The tool holder504includes an accessory tool attachment interface that is configured to releasably retain accessory tools, such as the blade100. The attachment portion102of the blade100includes an accessory attachment interface that is configured to mate with the tool attachment interface of the tool holder.

FIG. 6depicts a schematic diagram view of another embodiment of a straight cutting oscillating blade300having an attachment portion302, a cutting end304, a cutting zone306and a reinforcement308. The blade300further includes three cutout regions310a,310b,310clocated beyond the reinforcement308such that the reinforcement308is located between the cutting zone306and the cutout region310a,310b, or310c. The cutout regions310a,310b,310cform at least a portion of the blade300into a serpentine shaped region310that is configured to reduce the mass of the blade300and to lessen vibration of an oscillating tool driving the blade300. As described previously, cutout regions with other shapes are also contemplated.

FIG. 7depicts a schematic diagram view of another embodiment of a straight cutting oscillating blade400. Unlike the previous embodiments, the blade400is not provided with an oscillating interface for mounting the blade400to an oscillating tool. Examples of blade attachment systems usable to secure the blade400to an oscillating tool include, but are not limited to, those disclosed, for example, in the commonly owned U.S. Patent Application No. 62/012,564, entitled “Blade And Blade Guard Attachment System For An Oscillating Tool”, filed Jun. 16, 2014 by Rubens, the entirety of which is incorporated by reference in its entirety. An exemplary image of a blade attachment system for an oscillating blade that does not include an interface for mounting the blade to an oscillating tool is illustrated inFIG. 8.

Returning toFIG. 7, the blade400includes two cutting ends404a,404bon opposite end portions of the blade, two reinforcements408a,408b, and two cutting zones406a,406bformed between the cutting ends404a,404band the reinforcements408a,408b, respectively. The extra cutting end404bcan be used, for example, as additional or replacement cutting end when the other cutting end404ais worn out or damaged, such as after strenuous use or after some period of time. The blade400does not require the attachment portion found in blade100,200, and300; as the second end of the blade is now used as the additional cutting end404b.

The blade400further includes a cutout region410located between the reinforcement408a,408b. The cutout region410is configured to reduce a mass of the blade400and lessen vibration of an oscillating tool driving the blade400. The cutout region410can be in any form or shape. More than one cutout region410is also contemplated.

In one aspect of the present disclosure, a straight blade for straight cutting with an oscillating tool is contemplated that comprises a cutting end that includes cutting teeth, a cutting zone configured to engage the cutting teeth during a straight cut, a reinforcement that extends across the straight blade at an angle relative to the cutting end, and an attachment portion configured to attach the straight blade to an oscillating tool.

In one aspect, the cutting zone of a straight cutting oscillating blade is defined by a substantially triangular shape.

In one further aspect, a reinforcement extends from a corner of the cutting end of the blade to a point along a side of the straight blade.

In a further aspect, the reinforcement is a member attached to the straight blade.

In an additional aspect, the reinforcement is defined by geometry of the straight blade.

In an embodiment, the straight blade further comprises a cutout region located such that the reinforcement is between the cutout region and the cutting zone.

In a further aspect, a first side of the cutout region is substantially parallel to the reinforcement.

In an additional embodiment, a second side of the cutout region is substantially perpendicular to the reinforcement.

In a further embodiment, the cutout region is defined by at least one smooth curve.

In an additional embodiment, the cutout region is configured such that the blade includes a serpentine region.

In another aspect, the cutting zone is defined by a thin profile.

In another embodiment, the reinforcement comprises a first material, and at least one of the cutting teeth and cutting zone comprise a second material different than the first material.

In a further embodiment, a straight blade for straight cutting with an oscillating tool comprises, at each end, a respective cutting end that includes cutting teeth, a cutting zone configured to engage the cutting teeth during a straight cut, and a reinforcement that extends across the straight blade at an angle relative to the cutting end. The straight blade further includes at least one cutout region located between the respective cutting ends.

In a further aspect, such a straight blade does not include a mounting region.

In yet another embodiment, an oscillating tool comprises a mounting zone, and a straight blade mounted on the mounting zone. The straight blade is configured for straight cutting, and comprises a cutting end with cutting teeth, a cutting zone configured to engage the cutting teeth during straight cutting, a reinforcement at an angle relative to the cutting end, and an attachment portion configured to be attached to the mounting zone.

In an additional embodiment, an oscillating tool comprises a mounting zone for mounting a straight blade thereon without requiring engagement with a mounting region of the straight blade. A straight is mounted in the mounting zone, is configured for straight cutting, and comprises, at opposite ends, a respective cutting end with cutting teeth, a respective cutting zone configured to engage the cutting teeth during straight cutting, and a respective reinforcement at an angle to the respective cutting end.

It will be appreciated that variants of the above-described and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be subsequently made by those skilled in the art that are also intended to be encompassed by the disclosure.