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

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application Ser. No. 62/013,152 entitled “STRAIGHT CUTTING OSCILLATING BLADE” by Rubens et al., filed Jun. 17, 2014, the disclosure of which is hereby incorporated herein by reference in its entirety. 
     
    
     TECHNICAL FIELD 
       [0002]    This disclosure relates generally to power tools, and, more particularly, to oscillating tools for straight cutting. 
       BACKGROUND 
       [0003]    In general, oscillating tools are light-weight, handheld power tools capable of being equipped with a variety of tool accessories and attachments, such as cutting blades, sanding discs, grinding tools, and many others. These types of tools, referred to hereinafter as power tools, typically include a generally cylindrically-shaped main body that serves as an enclosure for an electric motor as well as a hand grip for the tool. The electric motor is operably coupled to a drive member, referred to herein as a tool mount, that extends from a portion of the main body of the power tool. The electric motor is configured to rotate and/or oscillate the tool mount at relatively high frequencies. 
         [0004]    The tool mount in turn is configured to secure different attachments so that as the tool mount is driven to move by the electric motor, an accessory tool secured to the mount is driven to perform work on a workpiece. Attachments usable with an oscillating tool include saw blades, sanders, raspers, grinders, scrapers, cutters, and polishers. Attachments can generally be mounted in a variety of orientations, which enables precision working in otherwise hard to reach areas. 
         [0005]    Straight blades including cutting teeth on an end side have been used as saw blade attachments for making plunge cuts, whereby the straight blade descends into a material being cut rather than moving transversely along a straight cut. Typically, oscillating blades used for straight cuts tend to flex during cutting, which can distort an otherwise straight cut, damage the blade, or damage the material being cut. Straight blades have been proposed that have an increased blade thickness to decrease flexing and improve straight cut performance. However, increasing blade thickness increases a mass of the oscillating tool and a vibration caused by the oscillating tool when in use, and can have other detrimental effects. What is needed, therefore, is a straight blade for an oscillating tool optimized for straight cuts. 
     
    
     
       DRAWINGS 
         [0006]      FIG. 1  is a plan view of an exemplary embodiment of a straight cutting oscillating blade. 
           [0007]      FIG. 2  is a plan view of another exemplary embodiment of a straight cutting oscillating blade. 
           [0008]      FIG. 3  is a perspective image of a cutting zone of an exemplary embodiment of a straight cutting oscillating blade. 
           [0009]      FIG. 4  is a perspective image of an exemplary embodiment of an oscillating tool with a straight cutting oscillating blade mounted thereon. 
           [0010]      FIG. 5  is a perspective image of another exemplary embodiment of an oscillating tool with a straight cutting oscillating blade mounted thereon. 
           [0011]      FIG. 6  is a plan view of another exemplary embodiment of a straight cutting oscillating blade. 
           [0012]      FIG. 7  is a plan view of another exemplary embodiment of a straight cutting oscillating blade. 
           [0013]      FIG. 8  is a perspective image of an exemplary embodiment of a blade attachment system for mounting an oscillating blade that does not include a mounting interface. 
       
    
    
     DETAILED DESCRIPTION 
       [0014]    For the purposes of promoting an understanding of the principles of the embodiments described herein, reference is now made to the drawings and descriptions in the following written specification. No limitation to the scope of the subject matter is intended by the references. This disclosure also includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the described embodiments as would normally occur to one skilled in the art to which this document pertains. 
         [0015]      FIG. 1  depicts a plan view of an embodiment of a straight cutting oscillating blade  100  having an attachment portion  102 , and a blade portion  104 . The attachment portion  102  can be configured in a known manner to attach the blade  100  to an oscillating tool ( FIG. 4 ) such that the blade  100  can be oscillated by the tool. The blade portion  104  includes lateral edges  120 ,  122  and a leading edge  124 . The lateral edges  120 ,  122  extend forwardly from the attachment portion  102 , and the leading edge  124  extends between the distal ends of the lateral edges  120 ,  122 . The leading edge  124  defines a cutting edge and may include cutting teeth configured to perform an operation on a workpiece, such as a straight cut. The blade  100  may also include a transition portion  118  that offsets the blade portion  104  of the blade from the attachment portion  102 . 
         [0016]    The blade  100  further includes a reinforcement structure  108  that extends across the blade portion  104  and defines a cutting zone  106  that encompasses the blade portion from the reinforcement structure to the leading edge portion  116 . The reinforcement structure is configured to increase a stiffness of the blade  100 , without increasing the thickness of the cutting zone  106  or increasing the inertial mass of the blade  100 . In the embodiment illustrated in  FIG. 1 , the cutting zone  106  has a substantially triangular shape, although cutting zones having other shapes are also contemplated. The reinforcement  108  extends from a corner  110  of the leading edge  116  and at least substantially across the blade  100  at an angle relative to the leading edge  116 . As can be seen in  FIG. 2 , the reinforcement  108  extends to a position on the lateral edge that is proximate the transition portion  118 . In some embodiments, the cutting zone  106  is defined at least in part by the reinforcement  108 . 
         [0017]    The reinforcement  108  as illustrated in  FIG. 1  may be a separate reinforcement member that has been suitably attached to the blade  100 . Alternatively, the reinforcement may be a stamped or formed geometry in the blade  100 . The reinforcement  108  may advantageously extend across an entire width of the blade  100 , so that the reinforcement  108  may be formed by a uniform stamping operation across the blade  100 . The reinforcement  108  is further configured to limit walking or flexing of the blade  100  during straight cutting. Due to inclusion of the reinforcement  108 , the cutting zone can be configured with a thinner profile than a conventional blade, resulting in a lower mass and less vibration, and more accurate cutting with less distortion. In an example, the cutting zone  106  has a thickness that is 25% thinner or more, relative to a conventional straight blade for an oscillating tool. 
         [0018]    As illustrated in  FIG. 1 , the blade  100  has a substantially rectilinear shape. In a non-limiting example, the width of the blade  100  can be from about 0.5 inches to about 4 inches, or more particularly, about 1.5 inches. A length of the blade  100  can be from about 2 inches to about 10 inches, or more particularly, about 5 inches. The cutting zone  106  can have a first thickness that is thinner than at least one of a thickness of the reinforcement  108  or a thickness of another region of the blade  100  beyond the reinforcement  108 . In an example, the cutting zone  106  can have a thickness of about 0.05 inches or less for a blade formed of stainless steel. Portions of the blade  100  proximate to the attachment portion may be rounded, beveled, or cut away for advantageous handling and attachment of the blade  100  to an oscillating tool. 
         [0019]    The blade  100  can be made using, for example, stainless steel, tungsten carbide, brass, cobalt, or any other suitable materials. In an embodiment, the cutting teeth of the cutting edge may include at least one different material, such as diamond, or carbide. In an embodiment, the blade  100  is made using a first material than is different from a second material used to make the reinforcement  108 . For example, the blade  100  can be made using stainless steel, and the reinforcement can be made using iron, plastics, carbon fiber, rubber, etc., or combinations thereof. 
         [0020]      FIG. 2  depicts a plan view of another embodiment of a straight cutting oscillating blade  200  having an attachment portion  202 , a blade portion  204 , a cutting zone  206  and a reinforcement  208 . In this embodiment, the blade  200  further includes a cutout region  210  located between the attachment portion  202  and the reinforcement  208  such that the reinforcement  208  is located between the cutting zone  206  and the cutout region  210 . The cutout region  210  is configured to reduce the mass of the blade  200  and to lessen vibration of an oscillating tool driving the blade  200 . 
         [0021]    As illustrated in  FIG. 2 , the cutout region  210  has a first side  212  that is substantially parallel to the reinforcement  208  and a second side  214  that is substantially perpendicular to the first side  212 . However, in other embodiments, cutout regions with other shapes are also contemplated. In an example, a cutout region is defined by at least one curved or beveled side. In another example, a first radius connects the first side  212  to the straight cutting oscillating blade  200 , and a second radius connects the second side  214  to the straight cutting oscillating blade  200 . The cutout region  210  may be formed with other elements of the blade  200 , such as in a common stamping operation. 
         [0022]      FIG. 3  depicts an exemplary image of a blade that demonstrates a cutting zone for a straight cut with a straight cutting oscillating blade. 
         [0023]      FIGS. 4-5  depict images of exemplary embodiments of oscillating tools with a straight cutting oscillating blade mounted thereon in conjunction with a workpiece upon which a straight cut has been performed using the oscillating tool. As can be seen in  FIGS. 4 and 5 , the oscillating tool  500  includes a portable housing  502 . A motor (not visible) is enclosed within the housing  502 . The motor is configured to oscillate a tool holder  504  that is located exterior to the housing. The tool holder  504  includes an accessory tool attachment interface that is configured to releasably retain accessory tools, such as the blade  100 . The attachment portion  102  of the blade  100  includes an accessory attachment interface that is configured to mate with the tool attachment interface of the tool holder. 
         [0024]      FIG. 6  depicts a schematic diagram view of another embodiment of a straight cutting oscillating blade  300  having an attachment portion  302 , a cutting end  304 , a cutting zone  306  and a reinforcement  308 . The blade  300  further includes three cutout regions  310   a,    310   b,    310   c  located beyond the reinforcement  308  such that the reinforcement  308  is located between the cutting zone  306  and the cutout region  310   a,    310   b,  or  310   c.  The cutout regions  310   a,    310   b,    310   c  form at least a portion of the blade  300  into a serpentine shaped region  310  that is configured to reduce the mass of the blade  300  and to lessen vibration of an oscillating tool driving the blade  300 . As described previously, cutout regions with other shapes are also contemplated. 
         [0025]      FIG. 7  depicts a schematic diagram view of another embodiment of a straight cutting oscillating blade  400 . Unlike the previous embodiments, the blade  400  is not provided with an oscillating interface for mounting the blade  400  to an oscillating tool. Examples of blade attachment systems usable to secure the blade  400  to an oscillating tool include, but are not limited to, those disclosed, for example, in the commonly owned U.S. Patent Application No. 62/012,564, entitled “Blade And Blade Guard Attachment System For An Oscillating Tool”, filed Jun. 16, 2014 by Rubens, the entirety of which is incorporated by reference in its entirety. An exemplary image of a blade attachment system for an oscillating blade that does not include an interface for mounting the blade to an oscillating tool is illustrated in  FIG. 8 . 
         [0026]    Returning to  FIG. 7 , the blade  400  includes two cutting ends  404   a,    404   b  on opposite end portions of the blade, two reinforcements  408   a,    408   b,  and two cutting zones  406   a,    406   b  formed between the cutting ends  404   a,    404   b  and the reinforcements  408   a,    408   b,  respectively. The extra cutting end  404   b  can be used, for example, as additional or replacement cutting end when the other cutting end  404   a  is worn out or damaged, such as after strenuous use or after some period of time. The blade  400  does not require the attachment portion found in blade  100 ,  200 , and  300 ; as the second end of the blade is now used as the additional cutting end  404   b.    
         [0027]    The blade  400  further includes a cutout region  410  located between the reinforcement  408   a,    408   b.  The cutout region  410  is configured to reduce a mass of the blade  400  and lessen vibration of an oscillating tool driving the blade  400 . The cutout region  410  can be in any form or shape. More than one cutout region  410  is also contemplated. 
         [0028]    In one aspect of the present disclosure, a straight blade for straight cutting with an oscillating tool is contemplated that comprises a cutting end that includes cutting teeth, a cutting zone configured to engage the cutting teeth during a straight cut, a reinforcement that extends across the straight blade at an angle relative to the cutting end, and an attachment portion configured to attach the straight blade to an oscillating tool. 
         [0029]    In one aspect, the cutting zone of a straight cutting oscillating blade is defined by a substantially triangular shape. 
         [0030]    In one further aspect, a reinforcement extends from a corner of the cutting end of the blade to a point along a side of the straight blade. 
         [0031]    In a further aspect, the reinforcement is a member attached to the straight blade. 
         [0032]    In an additional aspect, the reinforcement is defined by geometry of the straight blade. 
         [0033]    In an embodiment, the straight blade further comprises a cutout region located such that the reinforcement is between the cutout region and the cutting zone. 
         [0034]    In a further aspect, a first side of the cutout region is substantially parallel to the reinforcement. 
         [0035]    In an additional embodiment, a second side of the cutout region is substantially perpendicular to the reinforcement. 
         [0036]    In a further embodiment, the cutout region is defined by at least one smooth curve. 
         [0037]    In an additional embodiment, the cutout region is configured such that the blade includes a serpentine region. 
         [0038]    In another aspect, the cutting zone is defined by a thin profile. 
         [0039]    In another embodiment, the reinforcement comprises a first material, and at least one of the cutting teeth and cutting zone comprise a second material different than the first material. 
         [0040]    In a further embodiment, a straight blade for straight cutting with an oscillating tool comprises, at each end, a respective cutting end that includes cutting teeth, a cutting zone configured to engage the cutting teeth during a straight cut, and a reinforcement that extends across the straight blade at an angle relative to the cutting end. The straight blade further includes at least one cutout region located between the respective cutting ends. 
         [0041]    In a further aspect, such a straight blade does not include a mounting region. 
         [0042]    In yet another embodiment, an oscillating tool comprises a mounting zone, and a straight blade mounted on the mounting zone. The straight blade is configured for straight cutting, and comprises a cutting end with cutting teeth, a cutting zone configured to engage the cutting teeth during straight cutting, a reinforcement at an angle relative to the cutting end, and an attachment portion configured to be attached to the mounting zone. 
         [0043]    In an additional embodiment, an oscillating tool comprises a mounting zone for mounting a straight blade thereon without requiring engagement with a mounting region of the straight blade. A straight is mounted in the mounting zone, is configured for straight cutting, and comprises, at opposite ends, a respective cutting end with cutting teeth, a respective cutting zone configured to engage the cutting teeth during straight cutting, and a respective reinforcement at an angle to the respective cutting end. 
         [0044]    It will be appreciated that variants of the above-described and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements may be subsequently made by those skilled in the art that are also intended to be encompassed by the disclosure.