Tool accessory mounting interface

An accessory for a power tool includes a mounting interface for detachably mounting the accessory to a clamping device of the power tool. The mounting interface is configured to permit the accessory to be used with a wide variety of clamping devices, regardless of manufacturer. The accessory includes a mounting portion having a spindle slot configured to accommodate a drive spindle of the tool and pin openings that are arranged around the spindle slot. The pin openings are configured to receive pins which are arranged around a spindle of an oscillating power tool. When viewed in a cross section that is perpendicular to the first clamping face, at least a portion of opposed surfaces of at least one pin opening are non-parallel.

BACKGROUND

Oscillating power tools generally have a motor, an output shaft, and a transmission that connects the motor to the output shaft and converts rotary motion of the motor to oscillating motion of the output shaft. The output shaft is coupled to an accessory attachment mechanism that is used to removably attach various types of accessories, such as cutting tools, saw blades, and sanding tools, to the output shaft. Different brands of oscillating power tools tend to have different, often proprietary, accessory attachment mechanisms. In addition, the number of attachment schemes and types of accessories have increased over time. Thus, it is desirable to have accessories for oscillating power tools, where the accessories have a mounting interface that can be used with as many accessory attachment mechanisms as possible regardless of oscillating tool brand or manufacturer.

SUMMARY

Example embodiments of a tool accessory including the mounting interface relate to blades or other devices used with oscillating power tools. The term “oscillating” is used herein to refer to a back-and-forth motion in any direction whether it be in the same plane as a working edge of the accessory, as is often the case when referring to “oscillating tools” in general parlance, or reciprocating in a plane that is perpendicular to the working edge, as is the case when referring to “reciprocating saws” in general parlance. Therefore, embodiments for either type of motion, as well as others, are included in the scope of the claims presented herein.

The accessory is used to effect a change in a surface of a workpiece, and may perform sanding, scraping, cutting, grinding, scoring and/or other operations on the workpiece. To this end, the accessory includes a working portion and a mounting portion.

The working portion of the accessory includes a working edge that is applied against the workpiece to effect the desired change. In a cutting accessory (e.g., a cutting blade), the working edge defines a series of cutting teeth. In a sanding accessory (e.g., a sanding block), the working edge is an abrasive surface.

The mounting portion of the accessory includes features that permit mounting to a clamping device of a power tool. The mounting features include a spindle slot that receives a spindle of the clamping device, and pin openings that partially surround the spindle slot. The spindle slot and the pin openings are “through openings,” e.g., they are openings that extend through the thickness of the mounting portion between a first clamping face and a second clamping face of the mounting portion. The pin openings are shaped and dimensioned to receive pins provided on a clamping flange of the clamping device.

The accessory described herein includes a mounting interface that permits the accessory to be used with a wide variety of clamping devices, and thus may be considered to be a “universal” mounting interface. This is achieved by providing at least one of the pin openings of the mounting portion with a profile that, when viewed in a cross section that is perpendicular to the first clamping face, is non-rectangular since at least a portion of opposed surfaces of the pin opening is non-parallel. By this configuration, the pin opening has an irregular profile such that the pin opening has a first area in a location that is coplanar with the first clamping face and a second area in a location that is coplanar with the second clamping face, and the first area is less than the second area.

In some aspects, an accessory for oscillating power tools includes a working portion configured to perform an operation on a workpiece and a mounting portion configured to be clamped between a clamping flange and a spindle head of a tool holder of an oscillating power tool. The mounting portion includes a first clamping face that is configured to abut the clamping flange and a second clamping face that is spaced apart from the first clamping face and faces away from the first clamping face. The second clamping face is configured to abut the spindle head. The mounting portion includes a spindle slot that extends in an axial direction through the mounting portion from the first clamping face to the second clamping face. The spindle slot is configured to accommodate a spindle of an oscillating power tool. In addition, the mounting portion includes pin openings that extend in the axial direction through the mounting portion from the first clamping face to the second clamping face. The pin openings are arranged around the spindle slot and are configured to receive pins which are arranged around the spindle of an oscillating power tool. When viewed in a cross section that is perpendicular to the first clamping face, at least a portion of opposed surfaces of at least one pin opening are non-parallel.

In some embodiments, the portion of opposed surfaces of at least one pin opening adjoins the second clamping face.

In some embodiments, the portion of opposed surfaces of at least one pin opening is linear and at an acute angle with respect to the first clamping face.

In some embodiments, the portion of opposed surfaces of at least one pin opening is non-linear.

In some embodiments, the portion of opposed surfaces of at least one pin opening is curved.

In some embodiments, the portion of opposed surfaces of at least one pin opening corresponds to a first portion of opposed surfaces of at least one pin opening. When viewed in a cross section that is perpendicular to the first clamping face, a second portion of opposed surfaces of at least one pin opening adjoins the first clamping face, the first portion of opposed surfaces of at least one pin opening is linear and at a first angle with respect to the first clamping face, the second portion of opposed surfaces of at least one pin opening is linear and at a second angle with respect to the first clamping face, and the first angle is different from the second angle.

In some embodiments, the first angle is an acute angle and the second angle is substantially a right angle.

In some embodiments, the portion of opposed surfaces of at least one pin opening corresponds to a first portion of opposed surfaces of at least one pin opening. When viewed in a cross section that is perpendicular to the first clamping face, a second portion of opposed surfaces of at least one pin opening adjoins the first clamping face, the first portion of opposed surfaces of at least one pin opening is curved and defines a concavity with respect to the second clamping face, and the second portion of opposed surfaces of at least one pin opening is linear and at an angle with respect to the first clamping face.

In some embodiments, the portion of opposed surfaces of at least one pin opening corresponds to a first portion of opposed surfaces of at least one pin opening. When viewed in a cross section that is perpendicular to the first clamping face, a second portion of opposed surfaces of at least one pin opening adjoins the first clamping face, the first portion of opposed surfaces of at least one pin opening has a first thickness and the second portion of opposed surfaces of at least one pin opening has a second thickness. The term thickness refers to a dimension in a direction perpendicular to the first clamping face, and the first thickness is greater than the second thickness.

In some embodiments, the portion of opposed surfaces of at least one pin opening extends from the first clamping face to the second clamping face.

In some embodiments, the at least one pin opening is elongated and defines a long axis in a direction corresponding to a direction of elongation. The long axis of the at least one pin opening extends along a radius of a spindle longitudinal axis, where the spindle longitudinal axis extends axially and is centered in the spindle slot.

In some embodiments, the at least one pin opening has a first area in a location that is coplanar with the first clamping face and a second area in a location that is coplanar with the second clamping face, and the first area is less than the second area.

In some aspects, an accessory for oscillating power tools includes a working portion configured to perform an operation on a workpiece; and a mounting portion configured to be clamped between a clamping flange and a spindle head of a tool holder of an oscillating power tool. The mounting portion includes a first clamping face that is configured to abut the clamping flange, and a second clamping face that is spaced apart from the first clamping face and faces away from the first clamping face. The second clamping face is configured to abut the spindle head. The mounting portion includes a spindle slot that extends in an axial direction through the mounting portion from the first clamping face to the second clamping face. The spindle slot is configured to accommodate a spindle of an oscillating power tool. In addition, the mounting portion includes pin openings that extend in the axial direction through the mounting portion from the first clamping face to the second clamping face. The pin openings are arranged around the spindle slot and are configured to receive pins which are arranged around the spindle of an oscillating power tool. At least one pin opening has a first area in a location that is coplanar with the first clamping face and a second area in a location that is coplanar with the second clamping face, and the first area is less than the second area.

In some embodiments, when viewed in a cross section that is perpendicular to the first clamping face, at least a portion of opposed surfaces of at least one pin opening are non-parallel.

In some embodiments, the portion of opposed surfaces of at least one pin opening adjoins the second clamping face, is linear and at an acute angle with respect to the first clamping face.

In some embodiments, the portion of opposed surfaces of at least one pin opening adjoins the second clamping face and is non-linear.

In some embodiments, the portion of opposed surfaces of at least one pin opening corresponds to a first portion of opposed surfaces of at least one pin opening. When viewed in a cross section that is perpendicular to the first clamping face, a second portion of opposed surfaces of at least one pin opening adjoins the first clamping face, the first portion of opposed surfaces of at least one pin opening is linear and at a first angle with respect to the first clamping face, the second portion of opposed surfaces of at least one pin opening is linear and at a second angle with respect to the first clamping face, and the first angle is different from the second angle.

In some embodiments, the first angle is an acute angle and the second angle is substantially a right angle.

DETAILED DESCRIPTION

Referring toFIGS.1and2, an accessory100is mounted on (e.g., fixedly connected to) an output shaft of a power tool1. When used with an oscillating and/or rotating power tool1, the accessory100is driven to oscillate and/or rotate via a motor11disposed within a tool housing2of the power tool1. To this end, the power tool1includes a drive system10and an accessory attachment mechanism that includes a clamping device30at least partially positioned within the tool housing2. The clamping device30may be adjusted between a clamped position and an unclamped position. In the clamped position, the clamping device30connects the accessory100to the power tool1in such a way that it may be driven to oscillate by the motor. In the unclamped position the accessory100may be assembled with or removed from the power tool1. The accessory100includes a mounting portion130having a mounting interface that permits the accessory to be used with a wide variety of clamping devices, e.g., provides a “universal” mounting interface. The mounting portion130includes a spindle slot136and pin openings138that provide the mounting interface and are configured to accommodate multiple different clamping devices. The accessory100including the mounting portion130will be described in detail below.

The drive system10includes an electric motor11and a transmission13. The electric motor11includes a motor shaft12and is provided as any electric motor known to those of ordinary skill in the art. The transmission13is coupled to the motor shaft12and includes a drive lever14. The transmission13converts rotation of the motor shaft12into oscillatory movement of the drive lever14about an axis of oscillation15.

The clamping device30includes an output shaft31, a clamping flange34, a spindle46that terminates in a spindle head38, a follower60, an actuator provided as a cam50, a biasing spring62, and a handle64.

The output shaft31is rotatably supported in the housing2by an upper bearing assembly66and a lower bearing assembly68. The output shaft31defines a cavity33in which the biasing spring62and the spindle46are at least partially positioned. A lower portion32of the output shaft31extends from the housing2. The output shaft31is coupled to the drive lever14. Accordingly, the output shaft31oscillates about the axis of oscillation15, along with the drive lever14, when the motor11is energized. Specifically, the output shaft31rotates back and forth through a range of approximately two degrees to three degrees of rotation.

The clamping flange34is fixedly connected to the lower portion32of the output shaft31and is positioned outside of the housing2. The clamping flange34is coupled to the drive system10through the output shaft31. The clamping flange34oscillates about the axis of oscillation15with the output shaft31and in the same manner as the output shaft31when the electric motor11is energized.

The clamping flange34receives the accessory100and, in the illustrated embodiment, includes a plurality of protrusions or pins36. The pins36protrude away from the tool housing2and toward the spindle head38. The pins36are arranged in a circular pattern centered about the axis of oscillation15. When the accessory100is mounted in the clamping device30, the pins36are received in corresponding pin openings138provided in the accessory100, as discussed in detail below. The pins36serve as drive pins that transmit the motion of the clamping device30to the accessory100.

The spindle head38is provided on an end of the spindle46near the clamping flange34and serves as a second clamping flange of the clamping device30. The spindle head38defines a generally circular periphery39of greater diameter than the spindle46.

The spindle46extends upward from the spindle head38through the cavity33in the output shaft31. The spindle46defines a longitudinally extending spindle axis48that is coaxial with the axis of oscillation15. The spindle46and the spindle head38are moveable in a direction parallel to the axis of oscillation15as represented by arrows D1, D2inFIG.2; however, the spindle46is fixedly connected to the power tool1and is not removable from the power tool1during the normal course of operation, including when the accessory100is removed from the power tool1.

The follower60is fixed to an upper end of the spindle46opposite to the spindle head38and extends further outward from the spindle46. The follower60is at least partially positioned within the cavity33of the output shaft31. The follower60is a unitary component and includes a pair of protrusions that each have a corresponding follower surface that engages and/or interacts with the cam50. The follower60has a generally circular periphery and the protrusions are located on diametrically opposite sides from each other.

The cam50of the clamping device30is positioned within the housing2above the follower60and at least partially within the cavity33in the output shaft31. The cam50defines a generally circular periphery having a center point51that is aligned with the axis of oscillation15. The cam50includes a cam surface52positioned to interact with the follower60.

The cam50is rotatably positioned within the housing2for rotation about the center point51between a clamped position (FIG.1) and an unclamped position (FIG.2). When the cam50is in the clamped position, the clamping device30is in the clamped position. In addition, when the cam50is in the unclamped position, the clamping device30is in the unclamped position.

The handle64of the clamping device30is connected to the cam50with a fastening member such that rotation of the handle64results in rotation of the cam50. The handle64is shown inFIG.1with the clamping device30in the clamped position, and the handle is shown inFIG.2, with the clamping device in the unclamped position.

The biasing spring62is a compression spring positioned in the cavity33of the output shaft31between the output shaft31and the follower60. The spring62biases the follower60, the spindle head38, and the spindle46toward the cam50for each position of the cam50. When the clamping flange34has received an accessory100and the clamping device30is in the clamped position, the biasing spring62biases the spindle head38against the accessory100, thereby clamping the accessory100between the spindle head38and the clamping flange34.

The components of the clamping device30are formed from hard and wear resistant materials. Accordingly, the output shaft31, the clamping flange34, the spindle head38, the spindle46, the follower60, and the cam50may be formed from metal, hard plastics, and/or other like materials as known by those of ordinary skill in the art.

Referring toFIGS.3-8and26-33, the accessory100may be, for example, a cutting blade. In this example, the accessory100is a thin, rigid plate that has a broad first surface102, a broad second surface104that is opposite the first surface102, and a narrow peripheral surface (periphery)106that extends between the first and second surfaces102,104. The accessory100is generally rectangular when viewed in top plan view. By this configuration, the periphery106includes a first end106(1), a second end106(2) and a pair of parallel lateral sides106(3),106(4) that extend between the first and second ends106(1),106(2). The accessory100is elongate so that the lateral sides106(3),106(4) are longer than the first and second ends106(1),106(2). The accessory also includes a longitudinal midline112that is parallel to and midway between the respective lateral sides106(3),106(4).

The accessory100is non-planar, and includes a pair of closely spaced, parallel bends108(1),108(2) that are located closer to second end106(2) than the first end106(1). As a result, the accessory100includes a planar first portion disposed between the first end106(1) and the first bend108(1) referred to as the working portion120. The accessory100includes a planar second portion disposed between the second bend108(2) and the second end106(2) referred to as the mounting portion130. In addition, the accessory100includes a third portion110that extends between the working portion120and the mounting portion130and is disposed between the first and second bends108(1),108(2). The third portion110is angled relative to the working and mounting portions120,130so that the working portion120and the mounting portion130are parallel and offset with respect to each other in an axial direction. The term “axial direction” refers to an axis that is parallel to the spindle axis48, keeping in mind that the working and mounting portions120,130are perpendicular to the spindle46when the accessory100is mounted in the clamping device30. Thus, the term “axial direction” as used herein also refers to a direction that is perpendicular to the first and second surfaces102,104of the working and mounting portions120,130.

The working portion120of the accessory100includes a working edge122that is applied against a workpiece (not shown) to effect a desired change to the workpiece. The desired change may include cutting, shaping, polishing, etcetera. In this example in which the accessory100is a cutting accessory (e.g., a cutting blade), the working edge122defines a series of cutting teeth (not shown). In a different embodiment, for example when the accessory100is a sanding accessory (e.g., a sanding block), the working edge122may be an abrasive surface.

Within the mounting portion130of the accessory100, the first surface102is referred to as the first clamping face132that, in use, faces toward and abuts the clamping flange34of the clamping device30. In addition, within the mounting portion130of the accessory100, the second surface104is referred to as the second clamping face134that, in use, faces toward and abuts the spindle head38of the clamping device30. Thus, the second clamping face134is parallel to, and faces away from, the first clamping face132and is spaced apart from the first clamping face132a distance corresponding to a thickness of the accessory100.

The mounting portion130includes features that permit mounting to the clamping device30of the power tool1. The mounting features include a spindle slot136that receives the spindle46of the clamping device30. In addition, the mounting features include pin openings138that partially surround the spindle slot136. The spindle slot136and the pin openings138are “through openings,” e.g., they are openings that extend through the thickness of the mounting portion130between the first clamping face132and the second clamping face134.

The spindle slot136is a concave cutout that intersects the accessory second end106(2). When the accessory100is viewed in top plan view (FIGS.5and6), the spindle slot136is U shaped including linear portions136(1) that are joined by a curved portion136(2). The linear portions136(1) are parallel to the accessory lateral sides106(3),106(4), and the curved portion136(2) is semi-circular and opens facing the accessory second end106(2). In the illustrated embodiment, the curved portion136(2) has a diameter that is greater than the maximum diameter of the spindle46. The curved portion136(2) is centered on a slot axis136(3) that is perpendicular to the first and second clamping faces132,134. Depending on the manufacturer of the power tool1, when the accessory100is mounted in the clamping device30, the spindle axis48may coincide with the slot axis136(3) or may be slightly offset toward the second end106(2) with respect to the slot axis136(3). InFIG.5, the spindle axis48is illustrated as coinciding with the slot axis136(3), and the location of an alternative embodiment spindle axis248(discussed below with respect toFIGS.13-15) is illustrated as being offset relative to the slot axis136(3) along the accessory midline112.

In the linear portions136(1), the surface135of the spindle slot136is perpendicular to the first and second clamping faces132,134. However, in the curved portion136(2), the surface135of the spindle slot136is beveled with respect to both the first and second clamping faces132,134. As a result, when the spindle slot136is viewed in a cross section that is perpendicular to the first and second clamping faces132,134and passes through the curved portion136(2) (FIG.4), the spindle slot surface135is convex and defined by adjacent beveled portions140(1),140(2) that intersect at an apex140(3) that is midway between the first clamping face132and the second clamping face134. The beveled portions140(1),140(2) allow the spindle slot136to accommodate the spindle46while engaging the clamping flange34and the spindle head38for a wide variety of spindle and clamping flange configurations which are manufacturer dependent.

The pin openings138are arranged along an arc that surrounds the spindle slot136. The pin openings are shaped and dimensioned to receive pins36provided on the clamping flange34of the clamping device30. The pin openings138are positioned around the spindle slot136so as to be in alignment with the pins36on the clamping flange34. The pin openings138are sized to receive the pins36with very little clearance between the pins36and the pin openings138.

When the accessory100is viewed in top plan view, each of the pin openings138have a profile that is generally rectangular in shape, with the rectangular shape being elongated and having rounded corners. In addition, each of the pin openings138defines a long axis139in a direction corresponding to the direction of elongation. The long axis139of each pin opening138extends along a radius of the slot axis136(3). In the illustrated embodiment, the accessory100includes nine pin openings138(1),138(2),138(3),138(4),138(5),138(6),138(7),138(8),138(9). The long axis139of the fifth or central pin opening138(5) is coincident with the longitudinal midline112of the accessory100. Four pin openings138(1),138(2),138(3),138(4) are disposed between the central pin opening138(5) and a first lateral side106(3) of the accessory100, and four pin openings138(6),138(7),138(8),138(9) are disposed between the central pin opening138(5) and the other lateral side106(4) of the accessory100. The pin openings138(1),138(2),138(3),138(4),138(6),138(7),138(8),138(9) other than the central pin opening138(5) are collectively referred to as “lateral pin openings.”

As seen when the accessory100is viewed in a cross section that is perpendicular to the first and second clamping faces132,134and passes through the central pin opening138(5) (FIG.7), the cross-sectional shape of the central pin opening138(5) is rectangular. That is, opposed surfaces of the central pin opening138(5) are parallel to each other and perpendicular to the first and second clamping faces132,134.

As seen when the accessory100is viewed in a cross section that is perpendicular to the first and second clamping faces132,134and passes through at least one lateral pin opening, for example the second pin opening138(2) (FIG.8), each of the lateral pin openings138(1),138(2),138(3),138(4),138(6),138(7),138(8),138(9) has a profile shape that is non-rectangular. In particular, at least a portion of opposed surfaces142of the lateral pin openings138(1),138(2),138(3),138(4),138(6),138(7),138(8),138(9) are non-parallel.

The effect of providing the lateral pin openings138(1),138(2),138(3),138(4),138(6),138(7),138(8),138(9) with opposed surfaces, or portions thereof, that are non-parallel is to provide a relatively larger opening area A2at the intersection of the lateral pin opening138with the second clamping face134than the pin opening area A1at the intersection of the lateral pin opening138with the first clamping face132. In other words, each lateral pin opening has a first area A1in a location that is coplanar with the first clamping face132and a second area A2in a location that is coplanar with the second clamping face134, and the first area A1is less than the second area A2.

In the illustrated embodiment, with reference to the cross-sectional view of the lateral pin opening138(2), the surface142of the lateral pin opening138(2) has a first portion144that adjoins the second clamping face134and a second portion146that extends between the first portion144and the first clamping face132. The first portion144includes opposed surfaces144(1),144(2). Each of the opposed surfaces144(1),144(2) of the first portion144is linear and is at an acute first angle θ1 with respect to the first clamping face132. The second portion146includes opposed surfaces146(1),146(2). Each of the opposed surfaces146(1),142(2) of the second portion146is linear and is at a right second angle θ2 with respect to the first clamping face132. Thus, the first and second portion144,146are each at an angle relative to the first clamping face132, and the first angle θ1 is different from the second angle θ2. In the illustrated embodiment, the first angle θ1 is in a range of 25 degrees to 65 degrees, for example 45 degrees or substantially 45 degrees. In addition, the second angle θ2 is 90 degrees or substantially 90 degrees. As used herein, the term “substantially” refers to the specified angle plus or minus three degrees and is used to allow for manufacturing tolerances and variations.

The first portion144of the surface142of the lateral pin opening138(2) has a first thickness t1and the second portion146has a second thickness t2, where the term “thickness” refers to a dimension in a direction perpendicular to the first clamping surface132. The first thickness t1is greater than the second thickness t2. The second thickness t2is made shorter in order to provide a first portion144that is relatively big, for example sufficiently big to accommodate the pin configurations of various manufacturers.

Referring toFIGS.1-2and9-12, in use, the accessory100is securely attached to the power tool1via the clamping device30of the power tool1. Operation of the clamping device30to secure the accessory100to the power tool1will now be described in detail.

In operation, the clamping device30securely clamps the accessory100to the power tool1and is quickly and easily manipulated to release the accessory from the power tool1. As shown inFIG.1, the clamping device30is in the clamped position without an accessory100clamped between the clamping flange34and the spindle head38. To connect an accessory100to the power tool1the clamping device30is first moved to the unclamped position by rotating the handle64approximately 140 degrees to 190 degrees, and in one particular embodiment about 150 degrees. No separate tools are needed to move the clamping device30to the unclamped position.

Movement of the clamping device30from the clamped position to the unclamped position, results in the spindle head38being moved in a downward direction D1away from the clamping flange34. In particular, rotation of the handle64results in rotation of the cam50relative to the follower60. Accordingly, as the cam50is rotated toward the unlocked position, the portions of the inclined surfaces52in contact with the follower surfaces are positioned increasingly further in the downward direction D1, thereby forcing the follower60, the spindle46, and the spindle head38to move in the downward direction against the force of the biasing spring62to the position shown inFIG.2. In this way, the profile of the cam surface52determines the distance that the spindle head38moves as the handle is moved from the clamped position to the unclamped position.

When the handle64reaches the unclamped position, the follower protrusions become seated in detents of the cam50under the force of the biasing spring62. The handle64is moved easily to the unclamped position since the inclined cam surfaces offer a mechanical advantage when compressing the biasing spring62, and also since the length of the handle offers a mechanical advantage when rotating the cam50. Therefore, the clamping device30is operable by users of virtually all skill levels including users with reduced manual dexterity.

As shown inFIG.2, when the clamping device30is in the unclamped position the spindle head38is separated from the clamping flange34and the accessory100may be received by the outer flange. To connect the accessory100to the clamping flange34, the spindle46is moved into the spindle slot136(FIGS.9and10). Next, the pin openings138are aligned with the pins36and the mounting portion130is moved in an upward direction D2until the pins36extend into the pin openings138. The spindle46is not removed from the power tool1during connection of the accessory100to the power tool.

With the accessory100received by the clamping flange34, the handle64is moved to the clamped position to clamp the mounting portion130of the accessory100between the spindle head38and the clamping flange34. The cam50is rotated relative to the follower60as the handle64is moved to the clamped position. As the cam50is rotated, the cam protrusions exit the follower detents and the portions of the inclined surfaces52in contact with the protrusions are moved increasingly further in the upward direction D2. During this time, the biasing spring62maintains the surfaces of the follower60against the inclined surfaces52, such that the follower60, the spindle46, and the spindle head38move in the upward direction D2relative to the clamping flange34under the force of the biasing spring62. This movement brings the spindle head38into contact with the accessory100. When the handle64is rotated to the clamped position the biasing spring62forces the spindle head38firmly in the direction of the clamping flange34to clamp the mounting portion130between the spindle head38and the clamping flange34. Also in the clamped position, an air gap may be formed between the cam50and the follower60, such that the cam surface52does not contact the follower surfaces when the clamping device30is in the clamped position.

When the clamping device30is in the clamped position, the pins36of the clamping flange34extend through the first area A1of the pin openings138of the accessory mounting portion130and are received with a slip fit (FIGS.10and12). The pins36received in the lateral pin openings138(1),138(2),138(3),138(4),138(6),138(7),138(8),138(9) are disposed in the second portion146thereof (FIG.12). The pins36received in the central pin opening138(5) and a pair of diametrically opposed lateral pin openings138(2),138(8) substantially fill the respective openings138(2),138(5)138(8), whereas the remaining pins36have a relatively shorter dimension in a direction parallel to the long axis139of the corresponding pin openings138(1),138(3)138(4),138(6),138(7)138(9). In this embodiment, the pins36are seated at the radially outermost extent of each of the respective pin openings138(FIG.10).

In the illustrated embodiment, the spindle46is disposed in the spindle slot136with a gap between the spindle46and the surface135of the spindle slot136. The periphery39of the spindle head38underlies the second clamping face134of the accessory100, and the beveled portions140(1),140(2) and apex140(3) of the spindle slot curved portion136(2) overlie the spindle head38(FIG.11). By this configuration, the spindle head38is prevented f-om passing through the spindle slot136.

After the accessory100is clamped to the power tool1, the electric motor11may be energized to cause the accessory100to oscillate. The oscillation of the drive lever14causes the output shaft31to oscillate. The oscillation of the output shaft31is transferred to the clamping flange34and to the mounting portion130of the accessory100. The working end268of the oscillating accessory100may be placed in contact with a workpiece to cut or shape the workpiece. In general, the accessory100oscillates through a range of approximately two to three degrees.

Referring toFIGS.13-15, the accessory mounting portion130includes the spindle slot136and pin openings138which are configured permit the accessory100to be mounted to a variety of accessory attachment mechanisms regardless of manufacturer. In the power tool1illustrated inFIGS.1and2, the accessory attachment mechanism is exemplified by the clamping device30, which includes the clamping flange34having the pins36that engage the first portion144of the corresponding pin openings138of the accessory100. However, the clamping device30is not limited to this configuration. For example, some power tools are provided with an alternative embodiment clamping device230(FIGS.13-15) in which the clamping flange234is free of pins36while the spindle head238includes pins236that protrude toward the tool housing2and toward the clamping flange234. In addition, the diameter of the spindle246that supports the spindle head238may be relatively larger than the spindle46illustrated above. Thus, the pins236are inserted into the accessory100via the second clamping face134(e.g., via the second area A2) and reside in the first portion144of the respective pin opening138. The positioning of the pins236relative to the spindle axis48and each other may vary, depending on the manufacturer of the clamping device230.

To accommodate the pins236inserted via the second area A2and having positions relative to the spindle axis48that are different than those of the pins36described above, the lateral pin openings138(1),138(2),138(3),138(4),138(6),138(7),138(8),138(9) of the accessory100have a profile shape that is non-rectangular. In particular, each lateral pin opening138has a first area A1in a location that is coplanar with the first clamping face132and a second area A2in a location that is coplanar with the second clamping face134. The first area A1is shaped, dimensioned and positioned to accommodate pins36of a clamping device30in which the pins36protrude from the clamping flange34. The second area A2is shaped, dimensioned and positioned to accommodate the pins236of a clamping device230in which the pins236protrude from the spindle head238. In the illustrated embodiments, the second area A2is greater than the first area A1to accommodate the variations in placement, orientation, and size of the pins236.

For example, in the embodiment illustrated inFIGS.13-15, when the clamping device230is in the clamped position, the pins236of the spindle head238extend through the second area A2of the pin openings138of the accessory mounting portion130. The pins236received in the lateral pin openings138(1),138(2),138(3),138(7),138(8),138(9) are disposed in the first portion144thereof (FIG.15). In addition, the pins236received in the lateral pin openings138(1),138(2),138(3),138(7),138(8),138(9) are offset from the pin opening long axis139toward the accessory second end106(2) such that the respective pins236abut one surface142(1) of the respective opening138and are spaced apart from the opposed surface142(2) (FIGS.13and14). The pin236received in the central pin opening138(5) may have a slip fit or a clearance fit with respect to surfaces of the opening138(5) parallel to the opening long axis139and is seated at the radially innermost extent of the pin openings138(5).

In the illustrated embodiment, the spindle246is disposed in the spindle slot136with a clearance fit between the spindle246and the surface135of the spindle slot136. The spindle246has a slightly larger diameter than the spindle46of the earlier embodiment, whereby the spindle axis248of the spindle246is offset toward the accessory second end106(2) relative to the spindle axis48of the earlier-described spindle48(FIG.5). In addition, the spindle246may contact the curved portion136(2) of the spindle slot136at at least one point, for example along the midline112. The periphery239of the spindle head238underlies the second clamping face134of the accessory100, and the beveled portions140(1),140(2) and apex140(3) of the spindle slot curved portion136(2) overlie the spindle head238. By this configuration, the spindle head238is prevented from passing through the spindle slot136.

Referring toFIGS.16-21, the accessory100is not limited to having lateral pin openings138having the cross-sectional profile illustrated inFIG.8. For example, as seen inFIG.16, an alternative embodiment accessory300may include alternative embodiment lateral pin openings338. The accessory300is similar to the accessory100described above, and common reference numbers are used to refer to common elements. As seen when the accessory300is viewed in a cross section that is perpendicular to the first and second clamping faces132,134and passes through at least one lateral pin opening, for example the second pin opening338(2), each of the lateral pin openings338has a profile shape that is non-rectangular. In particular, each lateral pin opening338has a first area A1in a location that is coplanar with the first clamping face132and a second area A2in a location that is coplanar with the second clamping face134, and the first area A1is less than the second area A2.

In this embodiment, with reference to the cross-sectional view of the lateral pin opening338(2), the surface342of the lateral pin opening338(2) has a first portion343that adjoins the second clamping face134, a second portion344that adjoins the first portion343, a third portion345that adjoins the second portion344and a fourth portion346that adjoins both the third portion and the first clamping face132. The first portion343includes opposed surfaces343(1),343(2). Each of the opposed surfaces343(1),343(2) of the first portion343is linear and is at a third angle θ3 with respect to the first clamping face132. The second portion344includes opposed surfaces344(1),344(2). Each of the opposed surfaces344(1),344(2) of the second portion344is curved so as to be concave with respect to the second clamping face134. The third portion345includes opposed surfaces345(1),345(2). Each of the opposed surfaces345(1),345(2) of the third portion345is linear and is at an acute fourth angle θ4 with respect to the first clamping face132. The fourth portion346includes opposed surfaces346(1),346(2). Each of the opposed surfaces346(1),342(2) of the fourth portion346is linear and is at a right or substantially right fifth angle θ5 with respect to the first clamping face132. In the illustrated embodiment, the third angle θ3 is in a range of 50 to 70 degrees, for example 60 degrees, while the fourth angle θ4 is in a range of 20 to 40 degrees, for example 30 degrees. In this embodiment, each portion343,344,345,346is non-parallel to the first clamping face132. The first through third portions343,344,345are configured (e.g., shaped, dimensioned and positioned to) to define a concavity that receives the pins236of the clamping device230ofFIG.15, whereas the fourth portion346is configured to accommodate the pins30of the clamping device30ofFIGS.1and2.

The first through third portions343,344,345of the surface342of the lateral pin opening338(2) combine to have a first thickness t1and the fourth portion346has a second thickness t2, and the first thickness t1is greater than the second thickness2.

Referring toFIG.17, another alternative embodiment accessory400may include alternative embodiment lateral pin openings438. The accessory400is similar to the accessory100described above, and common reference numbers are used to refer to common elements. As seen when the accessory400is viewed in a cross section that is perpendicular to the first and second clamping faces132,134and passes through at least one lateral pin opening, for example the second pin opening438(2), each of the lateral pin openings438has a profile shape that is non-rectangular. In particular, each lateral pin opening438has a first area A1in a location that is coplanar with the first clamping face132and a second area A2in a location that is coplanar with the second clamping face134, and the first area A1is less than the second area A2.

In this embodiment, with reference to the cross-sectional view of the lateral pin opening438(2), the surface442of the lateral pin opening438(2) has a first portion444that adjoins the second clamping face134and a second portion446that extends between the first portion444and the first clamping face132. The first portion444includes opposed surfaces444(1),444(2). Each of the opposed surfaces444(1),444(2) of the first portion444is linear and is at an acute sixth angle θ6 with respect to the first clamping face132. The second portion446includes opposed surfaces446(1),446(2). Each of the opposed surfaces446(1),442(2) of the second portion446is linear and is at an acute seventh angle θ7 with respect to the first clamping face132. Thus, the first and second portions444,446are each at an angle relative to the first clamping face132, and the sixth angle θ6 the same as the seventh angle θ7. In the illustrated embodiment, the sixth and seventh angles are in a range of 25 degrees to 65 degrees, for example 45 degrees or substantially 45 degrees.

The first portion444of the surface442of the lateral pin opening438(2) has a first thickness t1and the second portion446has a second thickness t2, where the term “thickness” refers to a dimension in a direction perpendicular to the first clamping surface132, and the first thickness t1is greater than the second thickness t2.

Referring toFIG.18, another alternative embodiment accessory500may include alternative embodiment lateral pin openings538. The accessory500is similar to the accessory100described above, and common reference numbers are used to refer to common elements. As seen when the accessory500is viewed in a cross section that is perpendicular to the first and second clamping faces132,134and passes through at least one lateral pin opening, for example the second pin opening538(2), each of the lateral pin openings538has a profile shape that is non-rectangular. In particular, each lateral pin opening538has a first area A1in a location that is coplanar with the first clamping face132and a second area A2in a location that is coplanar with the second clamping face134, and the first area A1is less than the second area A2.

In this embodiment, with reference to the cross-sectional view of the lateral pin opening538(2), the surface442of the lateral pin opening538(2) has a first portion544that adjoins the second clamping face134and a second portion546that extends between the first portion544and the first clamping face132. The first portion544includes opposed surfaces544(1),544(2). Each of the opposed surfaces544(1),544(2) of the first portion544is linear and is at an acute eighth angle θ8 with respect to the first clamping face132. The second portion546includes opposed surfaces546(1),546(2). Each of the opposed surfaces546(1),542(2) of the second portion546is linear and is at an acute ninth angle θ9 with respect to the first clamping face132. Thus, the first and second portions544,546are each at an acute angle relative to the first clamping face132and the eighth angle θ8 is different than the ninth angle θ9. In the illustrated embodiment, each of the eighth and ninth angles θ8, θ9 is in a range of 20 degrees to 60 degrees, for example 40 degrees.

The first portion544of the surface542of the lateral pin opening538(2) has a first thickness t1and the second portion546has a second thickness t2, where the term “thickness” refers to a dimension in a direction perpendicular to the first clamping surface132, and the first thickness t1is greater than the second thickness t2.

Referring toFIG.19, another alternative embodiment accessory600may include alternative embodiment lateral pin openings638. The accessory600is similar to the accessory100described above, and common reference numbers are used to refer to common elements. As seen when the accessory600is viewed in a cross section that is perpendicular to the first and second clamping faces132,134and passes through at least one lateral pin opening, for example the second pin opening638(2), each of the lateral pin openings638has a profile shape that is non-rectangular. In particular, each lateral pin opening638has a first area A1in a location that is coplanar with the first clamping face132and a second area A2in a location that is coplanar with the second clamping face134, and the first area A1is less than the second area A2.

In this embodiment, with reference to the cross-sectional view of the lateral pin opening638(2), the surface642of the lateral pin opening638(2) has a first portion644that adjoins the second clamping face134and a second portion646that extends between the first portion644and the first clamping face132. The first portion644includes opposed surfaces644(1),644(2). Each of the opposed surfaces644(1),644(2) of the first portion644are curved so as to be concave with respect to the second clamping face134. In the illustrated embodiment, the opposed surfaces644(1).644(2) comprise a single arc having a radius R, but may alternatively be formed of a combination of arcs of differing radii. The second portion646includes opposed surfaces646(1),646(2). Each of the opposed surfaces646(1),642(2) of the second portion546is linear and is at a right, or substantially right, tenth angle θ10 with respect to the first clamping face132.

The first portion644of the surface642of the lateral pin opening638(2) has a first thickness t1and the second portion646has a second thickness t2, where the term “thickness” refers to a dimension in a direction perpendicular to the first clamping surface132, and the first thickness t1is greater than the second thickness t2.

Referring toFIG.20, another alternative embodiment accessory700may include alternative embodiment lateral pin openings738. The accessory700is similar to the accessory100described above, and common reference numbers are used to refer to common elements. As seen when the accessory700is viewed in a cross section that is perpendicular to the first and second clamping faces132,134and passes through at least one lateral pin opening, for example the second pin opening738(2), each of the lateral pin openings738has a profile shape that is non-rectangular. In particular, each lateral pin opening738has a first area A1in a location that is coplanar with the first clamping face132and a second area A2in a location that is coplanar with the second clamping face134, and the first area A1is less than the second area A2.

In this embodiment, with reference to the cross-sectional view of the lateral pin opening738(2), the surface742of the lateral pin opening738(2) has a first portion744that adjoins the second clamping face134and a second portion746that extends between the first portion744and the first clamping face132. The first portion744includes opposed surfaces744(1),744(2). Each of the opposed surfaces744(1),744(2) of the first portion744are curved so as to be concave with respect to the second clamping face134. In the illustrated embodiment, the opposed surfaces744(1),744(2) comprise a single arc having a radius R, but may alternatively be formed of a combination of arcs of differing radii. The second portion746includes opposed surfaces746(1),746(2). Each of the opposed surfaces746(1),742(2) of the second portion746is linear and is at an acute eleventh angle θ11 with respect to the first clamping face132. The eleventh angle θ11is in a range of 25 degrees to 65 degrees, for example 45 degrees.

The first portion744of the surface742of the lateral pin opening738(2) has a first thickness t1and the second portion746has a second thickness t2, where the term “thickness” refers to a dimension in a direction perpendicular to the first clamping surface132, and the first thickness t1is greater than the second thickness t2.

Referring toFIG.21, another alternative embodiment accessory800may include alternative embodiment lateral pin openings438. The accessory400is similar to the accessory100described above, and common reference numbers are used to refer to common elements. As seen when the accessory400is viewed in a cross section that is perpendicular to the first and second clamping faces132,134and passes through at least one lateral pin opening, for example the second pin opening438(2), each of the lateral pin openings438has a profile shape that is non-rectangular. In particular, each lateral pin opening438has a first area A1in a location that is coplanar with the first clamping face132and a second area A2in a location that is coplanar with the second clamping face134, and the first area A1is less than the second area A2.

In this embodiment, with reference to the cross-sectional view of the lateral pin opening438(2), the surface442of the lateral pin opening438(2) has a first portion444that adjoins the second clamping face134and a second portion446that extends between the first portion444and the first clamping face132. The first portion444includes opposed surfaces444(1),444(2). Each of the opposed surfaces444(1),444(2) of the first portion444is linear and is at an acute sixth angle θ6 with respect to the first clamping face132. The second portion446includes opposed surfaces446(1),446(2). Each of the opposed surfaces446(1),442(2) of the second portion446is linear and is at an acute seventh angle θ7 with respect to the first clamping face132. Thus, the first and second portions444,446are each at an angle relative to the first clamping face132, and the sixth angle θ6 the same as the seventh angle θ7. In the illustrated embodiment, the sixth and seventh angles are in a range of 25 degrees to 65 degrees, for example 45 degrees or substantially 45 degrees.

The first portion444of the surface442of the lateral pin opening438(2) has a first thickness t1and the second portion446has a second thickness t2, where the term “thickness” refers to a dimension in a direction perpendicular to the first clamping surface132, and the first thickness t1is greater than the second thickness t2.

Referring toFIGS.22-23, the accessory100is not limited to having a spindle slot136in which the curved portion136(2) has a semi-circular profile when viewed in top plan view. For example, as seen inFIGS.22-23, an alternative embodiment accessory900may include an alternative embodiment spindle slot936. The accessory900is similar to the accessory400described above with respect toFIG.17, and common reference numbers are used to refer to common elements. The accessory900includes a spindle slot936that is a concave cutout that intersects the accessory second end106(2). When the accessory900is viewed in top plan view (FIG.22), the spindle slot936is U shaped including linear portions936(1) that are joined by a curved portion936(2). The linear portions936(1) are parallel to the accessory lateral sides106(3),106(4), and the curved portion936(2) is a compound curve that opens facing the accessory second end106(2). As used herein, the term “compound curve” refers to the curved portion936(2) having a profile defined by a secondary curve portion938that is superimposed on the semicircular portion136(2) along the accessory midline112(FIG.23). As in the previous embodiment, the semicircular portion136(2) has a diameter that is greater than the maximum diameter of the spindle46. The secondary curve portion938may be elliptical in shape (shown) or may be semicircular and have a radius that is different than the radius of the semicircular portion136(2). The secondary curved portion938is dimensioned such that when the secondary curve portion938is superimposed on the semicircular portion, a protrusion939is formed at each of the two intersections between the semicircular portion136(2) and the secondary curve portion938. As a result, when the accessory900is mounted in the clamping device230, the spindle246abuts the protrusions936and a gap g exists between the surface of the spindle246and the secondary curve portion938. Since the accessory900contacts the surface of the spindle246at two circumferentially spaced locations via the protrusions939, the accessory900provides increased stability relative to some accessories that contact the spindle246at a single point.

The spindle slot936of the accessory900includes other features of the earlier described spindle slot136. For example, in the linear portions936(1), the surface of the spindle slot936is perpendicular to the first and second clamping faces132,134, while the curved portion936(2) is beveled (only beveled portion140(2) is shown inFIG.22) with respect to both the first and second clamping faces132,134.

Referring toFIGS.24and25, the protrusions939along the spindle slot936can be provided using other strategies. For example, another alternative embodiment accessory1000may include another alternative embodiment spindle slot1036. The accessory1000is similar to the accessory400described above with respect toFIG.17, and common reference numbers are used to refer to common elements. The accessory1000includes a spindle slot1036that is a concave cutout that intersects the accessory second end106(2). When the accessory1000is viewed in top plan view (FIG.24), the spindle slot1036is U shaped including linear portions1036(1) that are joined by a curved portion1036(2). The linear portions1036(1) are parallel to the accessory lateral sides106(3),106(4), and the curved portion1036(2) is a semicircular curve that opens facing the accessory second end106(2). As in the previous embodiments, the semicircular portion1036(2) has a diameter that is greater than the maximum diameter of the spindle46. The curved portion1036(2) differs from the curved portion136(2) described above in that the curved portion1036(2) includes a pair of protrusions1039that are spaced apart along the circumference of the curved portion1036(2). The protrusions1039are rounded as shown but are not limited to this configuration. Since the accessory1000includes the protrusions1039, when the accessory1000is mounted in the clamping device230, a gap g exists between the surface of the spindle246and the curved portion1036(2). In addition, the accessory1000contacts the spindle at each of the two protrusions1039. By contacting the surface of the spindle246at two locations via the protrusions1039, the accessory1000provides increased stability relative to some accessories that contact the spindle46,246at a single point.

The spindle slot1036of the accessory1000includes other features of the earlier described spindle slot136. For example, in the linear portions1036(1), the surface of the spindle slot1036is perpendicular to the first and second clamping faces132,134, while the curved portion1036(2) is beveled (only beveled portion140(2) is shown inFIG.25) with respect to both the first and second clamping faces132,134.

In the illustrated embodiments, the accessory100is a cutting blade having a generally rectangular profile when the accessory is viewed in top plan view, including a first end106(1) that is parallel to the second end106(2) and parallel lateral sides106(3),106(4), where the lateral sides106(3),106(4) are perpendicular to the first and second ends106(1),106(2). The accessory100is not limited to this configuration. For example, in some embodiments, the lateral sides106(3),106(4) may be non-parallel such that when the accessory is viewed in top plan view, the accessory100may have a generally trapezoidal or generally triangular profile. In other embodiments, the accessory100may have a curved or partial-circular or circular profile when viewed in top plan view.

In the illustrated embodiment, the accessory100includes a pair of closely spaced, parallel bends108(1),108(2) that are located closer to second end106(2) than the first end106(1). The accessory100is not limited to this configuration. For example, in some embodiments, the parallel bends108(1),108(2) may have a different location or omitted completely.

In the illustrated embodiment, the accessory100includes nine pin openings138(1),138(2),138(3),138(4),138(5),138(6),138(7),138(8),138(9) distributed about the spindle slot136. The accessory100is not limited to this configuration. For example, in some embodiments, the accessory100may include a greater or fewer number of pin openings.

In the illustrated embodiment, the accessory100includes eight lateral pin openings138(1),138(2),138(3),138(4),138(6),138(7),138(8),138(9) in which at least a portion of opposed surfaces of each lateral pin opening is non-parallel, and also includes a central pin opening138(5) in which opposed surfaces of the pin opening are parallel. The accessory100is not limited to this configuration. For example, in some embodiments, the accessory100may include a greater or fewer number of pin openings in which opposed surfaces of the pin opening are parallel or non-parallel.

In the illustrated embodiments, the lateral pin openings138(1),138(2),138(3),138(4),138(6),138(7).138(8),138(9), when viewed in cross-section, have opposed surfaces which are symmetric about the pin longitudinal axis139. However, the lateral pin openings138(1),138(2),138(3),138(4),138(6),138(7),138(8),138(9) are not limited to being symmetric about the pin longitudinal axis. In some embodiments, the lateral pin openings138(1).138(2).138(3),138(4),138(6).138(7),138(8),138(9) may be asymmetric about the pin longitudinal axis139.

Although the accessory100is illustrated as a cutting tool, specifically a cutting blade, the accessory is not limited to this embodiment. For example, in other embodiments the accessory may be configured to effect sanding, scraping, cutting, grinding, scoring and/or other operations on a workpiece. To this end, the working portion120may have a different shape and/or the cutting edge122may be replaced with a different cutting edge, a different cutting surface or an abrasive edge or surface, as required by the specific application.

The working portion of the accessory includes a working edge that is applied against the workpiece to effect the desired change. In a cutting accessory (e.g., a cutting blade), the working edge defines a series of cutting teeth. In a sanding accessory (e.g., a sanding block), the working edge is an abrasive surface.

Selective illustrative embodiments of the tool and the accessory are described above in some detail. It should be understood that only structures considered necessary for clarifying the tool and the accessory have been described herein. Other conventional structures, and those of ancillary and auxiliary components of the tool and the accessory, are assumed to be known and understood by those skilled in the art. Moreover, while working examples of the tool and the accessory have been described above, the tool and the accessory are not limited to the working examples described above, but various design alterations may be carried out without departing from the tool and the accessory as set forth in the claims.