Portable band saw

A portable band saw includes a serviceable/replaceable bumper system for allowing the band saw to be easily repaired if damaged from being dropped. An auxiliary handle is adjustably mounted to the band saw and is releasable from its position if subjected to a large force so as to avoid damage to the handle and tool housing. An adjustable guide shoe includes a toolless adjustment. The front and rear section of the band saw are disposed on opposite sides of a polymeric field case. Compression rods are used to isolate compression forces from the polymeric field case. An electric box assembly including a plastic component box is disposed between the field case and a front section of the band saw. A crash guard is mounted adjacent to the field case and includes a sight guide along an edge thereof and a rear blade guard formed integrally therewith.

FIELD

The present disclosure relates to various improvements to a portable band saw.

BACKGROUND

Many tradespersons, such as pipe fitters, steam fitters and electricians, routinely cut metal workpieces such as pipes, tubes and conduit with portable hand-held power saws. In some applications, such as when the end of a pipe or conduit is to be threaded, it is highly desirable that the cut be perpendicular to the axis of the workpiece so that the maximum axial deviation or runout of the cut is less than about one-thirty second of an inch. When this degree of accuracy is needed, the tradesperson was typically forced to employ a free-standing cutoff saw or a portable hand-held band saw. Free-standing cutoff saws, however, are not typically practical due to issues with their cost and size, as well as the free-standing (i.e., non-portable) nature of the saw.

Although portable hand-held band saws provide the tradesperson with an efficient yet portable means for cutting work pieces, these tools can be improved by improving their maintenance and damage prevention, increasing their functionality, reducing their weight and improving the accuracy of a cut made by the band saw.

SUMMARY

A portable band saw includes a serviceable/replaceable bumper system for allowing the band saw to be easily repaired if damaged from being dropped. The bumper system includes a rigid shroud removably mounted to the band saw and an elastomeric bumper mounted to said rigid shroud.

An auxiliary handle is adjustably mounted to the band saw and is releasable from its position if subjected to a large force so as to avoid damage to the handle and tool housing. The front section of the band saw includes at least one bore receiving a spring biased insert having at least one of a detent and a protrusion for engaging the other of a detent and a protrusion on the handle. The spring biased insert allows the handle to disengage from the insert when subjected to a large force, such as by being dropped.

An adjustable guide shoe is provided that includes a toolless adjustment mechanism to allow the position of the guide shoe to be easily adjusted.

The front and rear section of the band saw are disposed on opposite sides of a polymeric field case. Compression rods are used to isolate compression forces from the polymeric field case.

An electric box assembly including a plastic component box is disposed between the field case and a front section of the band saw. The plastic component box can house a control module and a light power supply. One or more routing cavities can extend from the component box and provide a covering for a wire of a wire harness connected to said control module. A light emitting diode can be mounted to a routing cavity of the component box and can be aligned with the band saw blade to cast a shadow along the cut line.

A crash guard is mounted adjacent to the field case for protecting the filed case from damage. The crash guard can include a sight guide along an edge thereof and a rear blade guard formed integrally therewith for shielding the user from the return blade.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features. Although the following description is related generally to portable band saws, it will be understood that the systems and features of the portable band saw, as described and claimed herein, can be used with any appropriate portable tool, such as an appropriate portable cutting device, for example, a circular saw, reciprocating saw, etc. Therefore, it will be understood that the following discussions are not intended to limit the scope of the appended claims.

With reference toFIG. 1, a portable band saw10is shown. The portable band saw10can be used to cut through various metal, metal alloy and/or polymeric work-pieces. The portable band saw10can include a housing12, a power system14, a saw blade system16and a lighting system18. The housing12can enclose and/or support each of the power system14, the saw blade system16and the lighting system18. The power system14can power the saw blade system16, such that the saw blade system16can cut through the desired structure. The lighting system18can illuminate a work surface associated with the cutting operation of the saw blade system16to facilitate the operation of the portable band saw10.

With reference toFIGS. 1 and 2, the housing12can include a first or front section20and a second or rear section22, which can be joined together by a field case21, one or more compression rods24and at least one tension screw/bolt26. As the front section20and the rear section22of the housing12can be substantially similar to a housing associated with a commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., the front section20and the rear section22will not be discussed in great detail herein. Briefly, however, the front section20and rear section22can be composed of a metal or metal alloy material, and can comprise cast aluminum alloy or magnesium alloy, for example. The front section20can include a first or auxiliary handle28, while the rear section22can include a second or trigger handle30. Each of the front section20and the rear section22can include a bumper system32.

The auxiliary handle28can provide additional stability for the user of the portable band saw10, and can be indexed at multiple angles to enable the user to select a comfortable position for the operation of the portable band saw10, which can improve the ease of use of the portable band saw10. The auxiliary handle28can be coupled to the front section20of the housing12and can pivot or rotate relative to the housing12. With additional reference toFIGS. 3-6, the auxiliary handle28can include a knob34(FIGS. 3 and 4), a washer36(FIG. 4), a first insert38(FIGS. 3 and 5), a second insert40(FIGS. 3 and 5), a handle body42(FIGS. 3,4and6) and a carriage bolt44(FIGS. 3 and 4).

With reference toFIGS. 3 and 4, the knob34can comprise any suitable graspable portion that can enable a user to easily rotate the knob34in a clockwise or counterclockwise direction while the user is holding the trigger handle30. The knob34can be rotated relative to the housing12in a clockwise direction to secure the auxiliary handle28to the housing12, and can be rotated in a counterclockwise direction to release the auxiliary handle28from the housing12. In this regard, the knob34can include a bore34a. The bore34acan include threads, which can threadably engage mating threads44aon the carriage bolt44. Thus, the rotation of the knob34relative to the housing12can move the knob34along the threads44aof the carriage bolt44to either tighten or lock the auxiliary handle28on the housing12, or to release or loosen the auxiliary handle28relative to the housing12, and thus, enable the auxiliary handle28to be pivoted or indexed relative to the housing12.

With reference toFIG. 4, the washer36can be positioned between the knob34and the first insert38to distribute the tightening or compressive force from the knob34over a surface of the first insert38. With reference toFIGS. 3 and 5, the first insert38can be coupled to a first bore46formed in the housing12, and the second insert40can be coupled to a second bore48formed in the housing12. It should be noted that although the first bore46and second bore48are identified as separate bores, the first bore46and second bore48could comprise a single bore formed through the housing12. Typically, the first bore46can be formed opposite the second bore48. The first insert38and second insert40can be coupled to the first bore46and second bore48through any suitable fastening technique, such as through the use of mechanical fasteners, a press-fit, a snap fit, welding and the like. Alternatively, the inserts38,40can be provided with flats that orient the inserts within the46,48and springs41(FIG. 5) can be disposed within the bores46,48to bias the inserts toward the handle42. Generally, the first insert38and second insert40can be composed of a resilient material, which can comprise a metal, metal alloy, polymer or combinations thereof. For example, the first insert38and second insert40can be composed of a metal or metal alloy and a polymer can be overmolded onto the metal or metal alloy, if desired. The first insert38and second insert40can each include multiple detents38a,40a, which can engage protrusions42aformed on the handle body42(FIG. 3). The multiple detents38a,40acan enable the handle body42to be pivoted or indexed and secured to the housing12in a variety of positions. The springs41allow the inserts38,40to be retracted out of engagement with the protrusions42aof the handle body when the handle42is subjected to a large force, such as by being dropped. The ability of the handle to move when subject to a large force, protects the handle42and housing from being damaged if dropped.

With reference toFIGS. 3 and 6, the handle body42can be generally U-shaped, and can include the protrusions42a. The protrusions42acan be formed on opposite annular projections50. The protrusions42acan be sized to engage the detents38a,40ato enable the handle body42to be secured or coupled to the housing12in any desired position. Generally, with reference toFIGS. 7-9, the handle body42can be angled or indexed relative to the housing12in any position from about zero degrees (FIG. 7) to about ninety degrees (FIG. 8). For example, as shown inFIG. 9, the handle body42can be coupled to the housing12at about forty-five degrees. With reference back toFIG. 6, the annular projections50can include throughbores52. The throughbores52can slideably engage the carriage bolt44to enable the handle body42to rotate or pivot about the carriage bolt44when the knob34is rotated accordingly, as shown inFIGS. 3 and 4.

With reference toFIGS. 3 and 4, the carriage bolt44can include the threads44aand a head44b. The threads44acan engage the bore34aof the knob34to enable the handle body42to be secured to or released from the housing12. The head44bcan be sized such that the head44bcan apply a compressive force against one of the annular projections50of the handle body42when the auxiliary handle28is coupled to the housing12, as shown best inFIGS. 7-9.

With reference toFIG. 1, the trigger handle30can be coupled to the rear portion22of the housing12. As the trigger handle30can be substantially similar to a trigger handle associated with the commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., the trigger handle30will not be discussed in great detail herein. Briefly, however, the trigger handle30can enable the user to activate or deactivate the portable band saw10, and can enable the user to guide the portable band saw10over a work-piece.

The housing12can include the bumper system32, as shown inFIG. 1. The bumper system32can be coupled to the front section20and the rear section22. The bumper system32can protect the portable band saw10from inadvertent falls from various heights. Further, the bumper system32can be easily replaceable such that the user of the portable band saw10can replace the bumper system32himself or herself at a job site, without requiring the user to take the portable band saw10to a service station. The bumper system32can generally be configured to absorb a significant shock load, which can thereby prevent damage to the housing12. By preventing damage to the housing12, the portable band saw10may remain operable after a significant fall. With additional reference toFIG. 10, the bumper system32can include a front bumper54that can be coupled to the front section20, and a rear bumper56that can be coupled to the rear section22.

With reference toFIGS. 10-12, the front bumper54can include a shroud54aand a bumper54b. The shroud54acan be shaped to conform to a shape of the front section20, and can include a first or top surface60, a second or side surface62and one or more coupling features64. The shroud54acan be a monolithic member, but could also comprise one or more members to enable partial replacement of the front bumper54, if desired. The shroud54acan be composed of any suitable high strength material, such as a metal, metal alloy or polymer, and for example, steel. The shroud54acan be coupled to the front section20, via any suitable mechanical fastening technique, such as through a snap-fit or the use of mechanical fasteners, for example, rivets, bolts, screws, etc. Generally, as shown inFIG. 10, the top surface60can protect a top surface20aof the front section20, while the side surface62can protect an annular area20bbelow the top surface20aof the front section20. The coupling features64can couple the top surface60of the shroud54ato the top surface20aof the front section20, and can couple the side surface62to the annular area20b. If mechanical fasteners are employed to couple the shroud54ato the housing12, then the coupling features64can comprise apertures, however, it will be understood that the coupling features64can comprise any desired feature to attach the shroud54ato the housing12, such as mating projections.

With continuing reference toFIGS. 10-12, the bumper54bcan be shaped to conform to a shape of the side surface62of the shroud54a, and as best shown inFIG. 12, can include an insert66, a polymeric member68and one or more coupling features70. The bumper54bcan be a monolithic member, but could also comprise one or more members to enable partial replacement of the front bumper54, if desired. The insert66can be composed of any suitable high strength material, for example, a metal, metal alloy or polymer, such as steel. The insert66can provide the bumper54bwith added rigidity. The insert66can be disposed adjacent to the side surface62of the shroud54awhen the bumper54bis coupled to the shroud54a.

The polymeric member68can be coupled adjacent to a surface66aof the insert66. The polymeric member68can be coupled to the insert66through any suitable technique, such as by overmolding the polymeric member68onto the insert66, or by insert molding the insert66within the polymeric member68. The polymeric member68can be composed of any suitable shock absorbing material, for example, rubber. The coupling features70can couple the bumper54bto the shroud54a. The bumper54bcan be coupled to the shroud54a, via any suitable mechanical fastening technique, such as through a snap-fit or the use of mechanical fasteners, for example, rivets, bolts, screws, etc. If mechanical fasteners are employed to couple the bumper54bto the housing12, then the coupling features70can comprise apertures that extend through both the insert66and the polymeric member68, however, it will be understood that the coupling features70can comprise any desired feature to attach the bumper54bto the housing12, such as mating projections.

With reference toFIG. 10, the rear bumper56can be coupled to the rear section22of the housing12. Generally, the rear bumper56can be coupled to a side22aof the rear section22, to protect an annular area surrounding a top surface22bof the rear section22. The rear bumper56can be annular, however, the rear bumper56can be shaped as desired to conform to the shape of the rear section22. The rear bumper56can be a monolithic member, but could also comprise one or more members to enable partial replacement of the rear bumper56, if desired. With reference toFIG. 13, the rear bumper56can include an insert72, a polymeric member74and one or more coupling features76.

The insert72can be composed of any suitable high strength material, for example, a metal, metal alloy or polymer, such as steel. The insert72can provide the rear bumper56with added rigidity. The insert72can be disposed adjacent to the side22aof the rear section22when the rear bumper56is coupled to the rear section22.

The polymeric member74can be coupled adjacent to a surface72aof the insert72. The polymeric member74can be coupled to the insert72through any suitable technique, such as by overmolding the polymeric member74onto the insert72, or by insert molding the insert72within the polymeric member74. The polymeric member74can be composed of any suitable shock absorbing material, for example, rubber.

The coupling features76can couple the rear bumper56to the rear section22. The rear bumper56can be coupled to the rear section22, via any suitable mechanical fastening technique, such as through a snap-fit or the use of mechanical fasteners, for example, rivets, bolts, screws, etc. If mechanical fasteners are employed to couple the rear bumper56to the housing12, then the coupling features76can comprise apertures that extend through both the insert72and the polymeric member74, however, it will be understood that the coupling features76can comprise any desired feature to attach the rear bumper56to the housing12, such as mating projections.

With reference toFIG. 2, the field case21can be coupled between the front section20and the rear section22of the housing12. Generally, the field case21can be composed of a polymeric material, and can house at least a portion of the power system14. The field case21can include a first bore21a, a second bore21band a third bore21c. The first bore21a, the second bore21band the third bore21ccan extend at least partially through the field case21. For example, the first bore21aand the second bore21bcan be formed in the field case21such that a center area of the first bore21aand second bore21bcan be devoid of the field case21to enable a portion of the saw blade system16to be coupled to the field case21, via the compression rods24, as will be discussed. The first bore21aand the second bore21bcan be disposed at one side of the field case21and can be sized to receive the compression rods24. The third bore21ccan pass through a side of the field case21opposite the first bore21aand second bore21b. The third bore21ccan be sized to receive the tension screw/bolt26.

With reference toFIGS. 2 and 14, the compression rods24can be coupled between the front section20and the rear section22. A first compression rod24acan be received in the first bore21a, and a second compression rod24bcan be received in the second bore21bof the field case21, as shown inFIG. 14. The front section20and the rear section22can retain the compression rods24within the field case21. The compression rods24can receive a compression load C that can be generally inherent in the portable band saw10, and thus, the compression rods24can relieve the field case21from the compression load C, which can remove the compliant nature associated with the field case21being composed of a polymeric material. The compression rods24can also couple at least a portion of the saw blade system16to the field case21, as will be discussed herein.

With continued reference toFIGS. 2 and 14, the tension screw/bolt26can be received through the third bore21cof the field case21, and can extend from the front section20to the rear section22. The tension screw/bolt26can be threaded into a bore80defined in the rear section22, which can serve to retain the tension screw/bolt26within the bore21c. The tension screw/bolt26can receive a tension or tensile load T that can be generally inherent in the portable band saw10, and thus, the tension screw/bolt26can relieve the field case21from the tensile load T, which can remove the compliant nature associated with having the field case21composed of a polymeric material.

With reference toFIG. 15, the power system14can be encased by the housing12. The power system14can drive the saw blade system16to cut the work-piece. The power system14can include a trigger100, a motor102and a control system104via one or more wires100b(shown inFIG. 16). As the trigger100and motor102can be substantially similar to a trigger and motor associated with a commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., the trigger100and motor102will not be discussed in great detail herein. Briefly, however, the trigger100can include an actuator100athat can be in communication with the control system104. The actuator100acan protrude from the trigger handle30to enable a user to activate or deactivate the portable band saw10. Based on the input from the user, the actuator100acan transmit a signal to the control system104to activate the motor102.

With reference toFIG. 15, the motor102can be a DC motor, such as a brushless DC motor. The motor102can be housed in the field case21, and can be responsive to and in communication with the control system104. The motor102can also be coupled to the saw blade system16, via an output shaft, for example, to drive the saw blade system16. As will be discussed, based on the input received by the actuator100a, the control system104can provide the motor102with an appropriate current at an appropriate voltage phase angle to drive the saw blade system16.

The control system104can be coupled to a first end21dof the field case21, adjacent to the motor102. The control system104can be operable to activate and deactivate the motor102based on the user input received from the trigger100. With reference toFIGS. 15-18, the control system104can include a component box106(FIGS. 15,17and18), a controller108(FIG. 18), a lighting power supply110(FIG. 18) and a wiring harness112(FIGS. 16-18).

With reference toFIGS. 17 and 18, the component box106can be composed of a polymeric material, which can serve to electrically insulate the electrical components within the component box106from the metallic portions of the housing12, such as the front section20and the rear section22. The component box106is received in a cavity23in a rear portion of the front section20, as illustrated inFIGS. 10 and 15. The component box106can include apertures114, a component cavity116, a first routing cavity118, a second routing cavity120, and coupling members122. The apertures114can receive mechanical fasteners, such as screws, bolts, etc. to couple the component box106to the field case21. The component cavity116can be generally rectangular, and can have a depth sized to receive and retain the controller108and the lighting power supply110within the component box106, as shown inFIG. 17. The first routing cavity118and second routing cavity120can be sized to enable wires from the wiring harness112to be routed away from the metallic portions of the housing12. The coupling members122can retain the controller108and the lighting power supply110within the component box106. The coupling members122can comprise flexible arms to enable the controller108and the lighting power supply110to be inserted into the component box106.

With reference toFIG. 18, the controller108can be in communication with and responsive to the trigger100and the motor102to enable the operation of the portable band saw10, as will be discussed. The controller108can also be in communication with and responsive to the lighting system18to activate or deactivate the lighting system18, as will also be discussed herein. It should be understood that as used herein, the term controller refers to an application specific integrated circuit (ASIC), an electronic circuit, a processor (shared, dedicated, or group) and memory that execute one or more software or firmware programs, a combinational logic circuit, or other suitable components that provide the described functionality. Further, as the controller108can be substantially similar to a controller associated with a commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., the controller108will not be discussed in great detail herein. Briefly, however, the controller108can provide a selected current at a selected voltage phase angle to the motor102from a field power source (not shown) based on the signal received from the actuator100a. The controller108can also provide current to the lighting system18from the lighting power supply110based on a signal received from the lighting system18, as will be discussed.

With reference toFIG. 18, the lighting power supply110can comprise any suitable power source capable of providing current to the lighting system18, such as a battery, capacitor, etc. The lighting power supply110can include members110ato couple the wiring harness112to the component box106. The wiring harness112can include apertures formed in a projection112athat can receive the members110ato couple the wiring harness112to the component box106. Generally, the wiring harness112can be press-fit onto the members110a.

With reference toFIG. 16, the wiring harness112can include one or more controller connections124, a lighting connection126, a lighting power supply connection128and a feedback coil130. The controller connections124, the lighting connection126, the lighting power supply connection128and the feedback coil130can be overmolded with a polymeric material to form the wiring harness112. As the controller connections124, the lighting connection126and the lighting power supply connection128can be similar to the connections employed with the commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., the controller connections124, the lighting connection126and the lighting power supply connection128will not be discussed in great detail herein. The feedback coil130can be disposed within a center132of the overmolded wiring harness112, which can be adjacent to the motor102when the component box106is coupled to the field case21. The feedback coil130can sense the magnetic field generated by the motor102, and can communicate this information to the controller108via an appropriate one of the controller connections124. Based on the signal from the feedback coil130, the controller108can increase or decrease the speed of the motor102. By incorporating the feedback coil130within the center132of the overmolded wiring harness112, the feedback coil130can remain in the same position during the use of the portable band saw10, which can improve the accuracy of the signal received from the feedback coil130.

With reference toFIG. 19, the saw blade system16can be driven by the motor102of the power system14. The saw blade system16can include a blade200, one or more pulleys202, a shoe204, a crash plate system206and a sight guide208. The blade200can comprise a conventional band saw blade, such as a Bi-Metal Portable Band Saw Blade, model DW3891, commercially available from DeWALT Industrial Tool Co. of Baltimore, Md. The pulleys202can be substantially similar to pulleys associated with the commercially available Heavy-Duty Deep Cut Variable Speed Band Saw, model D28770, manufactured by DeWALT Industrial Tool Co. of Baltimore, Md., and thus, the pulleys202will not be discussed in great detail herein. Briefly, however, one of the pulleys202can be coupled to the motor102to drive the blade200around the housing12.

With reference toFIGS. 20-22, the shoe204can be positioned adjacent to the work-piece to support the work-piece during the operation of the portable band saw10. The shoe204can be configured to enable the user of the portable band saw10to adjust a position of the shoe204relative to the work-piece without requiring tools. The shoe204can include a shoe body210, a block212, a stud214and a lever216.

With reference toFIGS. 20 and 21, the shoe body210can define a first end218, a second end220, a first or front side222and a second or rear side224. The first end218can include one or more apertures226and a blade passage228. The apertures226can be sized to receive one or more mechanical fasteners226a, such as screws, bolts, etc., to couple the shoe body210to the block212. The blade passage228can enable the blade200to pass through the shoe body210. The second end220of the shoe body210can be positioned adjacent to the work-piece when the shoe204is coupled to the housing12. The front side222can face the front section20when the shoe204is coupled to the rear section22. The rear side224can be opposite the front side222, and thus, can be adjacent to the rear section22when the shoe204is coupled to the rear section22. The rear side224can also include a lip224a(FIG. 21). The lip224acan cooperate with the block212to couple or clamp the shoe body210to the rear section22of the housing12.

The block212can be coupled to the shoe body210via the mechanical fasteners226a. The block212can include a projection230, a clamping surface232and mating features234. With reference toFIG. 22, the projection230can be generally elliptical, and can be sized to slide within a slot236formed in the rear section22of the housing12. As will be discussed, the block212can cooperate with the slot236to enable the shoe body210to be positioned and secured in any desired position along a length of the slot236. The slot236can comprise a T-slot to enable only the projection230of the block212to be received in and slide within the slot236. As shown inFIG. 20, the projection230can define apertures230afor receipt of the mechanical fasteners226ato couple the block212to the shoe body210, and thus, the apertures230acan be threaded, if necessary, to mate with the mechanical fasteners226a.

With reference toFIGS. 20 and 22, the clamping surface232can cooperate with the lip224ato couple or clamp the shoe204to the rear section22of the housing12. In this regard, the rear section22of the housing12can include a rail238adjacent to the slot236(FIG. 22). When the projection230is positioned within the slot236, the lip224acan abut against a first side of the rail238and the clamping surface232can abut against a second side of the rail238to clamp the shoe204to the housing12. With reference toFIG. 21, the clamping surface232can include a taper232a. The taper232acan enable the block212to be forced tightly against the rail238to firmly clamp the shoe body210to the housing12.

With reference toFIGS. 20-22, the mating features234can be defined on a surface opposite the clamping surface232. The mating features234can include any feature capable of engaging the stud214in a variety of positions, such as ridges, angled projections, detents, etc. The mating features234can engage the stud214such that a force applied to the stud214, via the lever216, can be applied to the block212to clamp the shoe204to the housing12. Thus, the mating features234can cooperate with the stud214to lock or secure the shoe204in a desired vertical position relative to the housing12.

With reference toFIGS. 20 and 22, the stud214can include a first end240and a second end242. The first end240of the stud214can include at least one mating feature240a. The mating feature240acan be configured to engage the mating features234on the block212to transmit a torque from the lever216to the block212to clamp the shoe204to the housing12. For example, if the mating features234of the block212comprise angled projections, then the mating feature240aof the stud214can comprise a valley. The second end242of the stud214can be configured to couple the lever216to the stud214, and thus, the second end242can define a bore that can be threaded, keyed, notched, etc. to couple the lever216to the stud214.

With reference toFIGS. 20 and 22, the lever216can include a first end216athat can couple the lever216to the stud214, and a second end216bthat can receive an input from the user of the portable band saw10. The first end216acan be configured to mate within the bore242aof the second end242of the stud214, and thus, the first end216acan be threaded, keyed, notched, etc. to fixedly couple the lever216to the stud214. In addition, it should be understood that although the stud214and lever216are described herein as being discrete elements, the stud214and lever216could also be integrally formed. The second end216bof the lever216can be sized such that the user can easily grasp the lever216to rotate the lever216clockwise or counterclockwise relative to the housing12. In this regard, the lever216can be rotated clockwise to apply the torque to the block212, via the stud214, to clamp the shoe204in a desired position relative to the housing12. The lever216can be rotated counterclockwise to release the torque from the block212, by disengaging the mating features234of the block212from the mating feature240aof the stud214, to enable the projection230of the block212to be slid into a desired position within the slot236. Thus, the lever216can enable tool-less adjustment of the shoe204relative to the housing12, which can enable quick adjustments of the shoe204on a job site.

With reference to FIGS.19and23-25, the saw blade system16can also include the crash plate system206. The crash plate system206can protect a bottom250of the field case21from damage that may be caused by the portable band saw10contacting the work-piece after the cutting operation due to the inherent follow through motion of the portable band saw10. The crash plate system206can include a crash plate252and a blade guard254. The crash plate252and blade guard254can be discrete members, or can be integrally formed into a monolithic member. The crash plate252and blade guard254can be composed of any suitable high strength material, such as a metal, metal alloy or resilient polymer. The crash plate252can protect the field case21from damage, while the blade guard254can protect the user from a rear section200aof the blade200(FIG. 25).

The crash plate252can be configured to mate with the bottom250of the field case21, and for example, can be generally concave in shape. As shown inFIG. 24, the crash plate252can also be sized to fit in the void defined between the first bore21aand second bore21bof the field case21, so that the compression rods24a,24bcan be used to couple the crash plate252to the field case21. It will be understood that any suitable technique could be used to couple the crash plate252to the field case21, such as welding, adhesives, mechanical fasteners, etc. The crash plate252can include a top surface256, a rear surface258, a first side260, a second side262and throughbores264.

With reference toFIGS. 23 and 24, the top surface256can be positioned adjacent to the field case21, and can be generally smooth to mate with a generally smooth exterior of the field case21. The rear surface258can be opposite the top surface256, and can include one or more crush ribs258a. The crush ribs258acan absorb and distribute forces incurred when the portable band saw10inadvertently contacts the work-piece. The first side260can be coupled to the sight guide208, and the second side262can be coupled to the blade guard254. The throughbores264can be sized to slideably receive the compression rods24therethrough to couple the crash plate252to the field case21(FIG. 23).

With reference to FIGS.19and23-25, the blade guard254can be coupled to or formed on the second side262of the crash plate252. As discussed, the blade guard254can protect or guard the user from the rear portion200aof the blade200(FIG. 25), and can also shield the blade200from debris or objects adjacent to the work-piece. The blade guard254can define a passage254a. The passage254acan be sized to enable the blade200to pass therethrough, and can generally have a depth configured such that a majority of the blade200is disposed within the passage254a.

With reference toFIGS. 24 and 26, the sight guide208can be coupled to the first side260of the crash plate252(FIG. 24). In this regard, the sight guide208can be coupled to the first side260such that the sight guide208can extend substantially an entire length of the first side260of the crash plate252. The sight guide208can be comprised of any suitable material, such as a metal, metal alloy or polymer, that can be coated with a color, which contrasts with the field case21, such as red, to enable the user to easily view the sight guide208. The sight guide208can be coupled to the crash plate252via any suitable technique, such as molding, adhesives, mechanical fasteners, etc. For example, the sight guide208can comprise a polymeric material that can be adhesively coupled to the crash plate252, or the sight guide208can comprise a polymeric coating, such as paint, that can be applied to the first side260of the crash plate252. The sight guide208can assist the user in predicting the cutting plane of the blade200, without reducing or altering the blade200. In use, the user can align the sight guide208with a line or scribe on the work-piece and maintain this alignment throughout the cutting operation, which can assist the user in producing accurate cuts.

With reference toFIGS. 27-29, the lighting system18can illuminate the work-piece, generally in an area adjacent to and encompassing the desired cutting area or cutting path through the work-piece. The lighting system18can be housed within the component box106of the control system104on the front section20of the housing12. The lighting system18can include a light source300(FIG. 29), a printed circuit board (PCB)302(FIG. 29), a baffle304(FIGS. 28 and 29), a housing306(FIGS. 28 and 29) and a switch308(FIG. 27).

With reference toFIGS. 27 and 29, the light source300can comprise any suitable light emitting device, such a light emitting diode (LED), organic light emitting diode (OLED), etc. If a LED is employed as the light source300, the LED can comprise a one-half watt LED. The light source300can emit light rays R onto the work-piece to aid the user in the cutting operation. The light source300can be coupled to the PCB302.

With reference toFIG. 29, the PCB302can be in communication with and responsive to the controller104, via a connector302a, to receive power or current from the lighting power supply110. The PCB302can include suitable circuitry to power the light source300with the power received from the lighting power supply110. Upon receipt of the current from the controller104, the PCB302can activate the light source300to illuminate the work-piece.

With reference toFIGS. 28 and 29, the baffle304can be positioned over the light source300and the PCB302. The baffle304can be generally annular, and can be sized to surround the light source300and the PCB302such that the PCB302is hidden from the view of the user. The baffle304can be composed of any suitable heat resistant material, such as a metal, metal alloy or polymer. The baffle304can include a bore304a, a shade304band keys304c. The bore304acan be sized to enable the light source300and the PCB302to be retained within the baffle304. The shade304bcan be generally V-shaped, and can cover at least a portion of the light source300. The shade304bcan prevent the light rays from the light source300from shining in the user's eyes. The keys304ccan ensure that the baffle304is properly inserted within the housing306, and that the baffle304does not rotate relative to the housing306.

The housing306can couple the lighting system18to the component box106. The housing306can be composed of any suitable material, such as a metal, metal alloy or polymer, and can generally comprise a translucent polymer. The housing306can include a bore306aand at least one coupling feature306b. The bore306acan be configured to receive the baffle304, and can include mating keys312. The mating keys312can engage the keys304cof the baffle304, which can ensure that the baffle304is properly orientated and remains properly orientated within the housing306. The coupling feature306bcan couple the housing306to the component box106. For example, the coupling feature306bcan comprise a bore for receipt of a mechanical fastener, such as a screw, bolt, etc. to couple the housing306to the component box106, as shown inFIG. 15.

With reference toFIGS. 15 and 27, the switch308can also be coupled to the component box106, and can be in communication with the controller108. The switch308can be coupled to the component box106such that the switch308can be easily manipulated by the user. In this regard, the switch308can enable the user to activate or deactivate the light source300. Thus, based on the user input received, the switch308can transmit a signal to the controller108, which can then transmit or cease transmitting power to the PCB302, effectively activating or deactivating the light source300.

In order to assemble the lighting system18, the light source300can be coupled to the PCB302, and that assembly can be inserted into the baffle304. Then, the baffle304can be inserted into the housing306, which can then be coupled to the component box106. The user can then manipulate the switch308to activate or deactivate the light source300. Thus, the lighting system18can be easily assembled and coupled to the portable band saw10to enable a user to selectively illuminate the work-piece, while not projecting light rays into the user's eyes.