Patent Publication Number: US-2021170621-A1

Title: Power Tool Attachment Saw

Description:
CROSS REFERENCE TO THE RELATED APPLICATION 
     This application claims priority under 35 U.S.C. § 119 to U.S. patent application Ser. No. 15/656,329 filed Jul. 21, 2017. 
     FIELD OF THE INVENTION 
     The present invention relates to a power tool attachment and, more particularly, to an oscillating power tool attachment saw for cutting drywall. 
     BACKGROUND 
     Modern buildings including homes, offices and other structures often use drywall to cover interior walls and ceilings. During installation, an installer will cut standard sheets of drywall to fit the building interior, and then make more specific cuts for outlet boxes for electrical outlets and light switches. To perform these cuts, the installer will commonly use a knife, a box cutter or other known cutting implement to partially cut through one side of the drywall. The installer then is required to break, fold over and then finish cutting the craft paper on the opposite side. This known process is tedious and causes gypsum to be scattered about the prep and work area. 
     More recently, installers have turned to power tools, such as oscillating power tools, to make these common cuts. Known oscillating power tools, for instance, provide vibratory motion for an attachment to cut through the drywall with ease. However, many known attachments for these oscillating power tools still require a large number of independent actions to perform accurate cuts. For example, the installer still needs to take several measurements to accurately match the dimensions of the opening for a desired position along the drywall. Furthermore, since several cuts are performed, the oscillating power tool causes gypsum and cut pieces to be scattered about the prep and work area, which causes more time for clean up. Therefore, there is a need for an improved tool attachment to cut openings in drywall that is more convenient, efficient, and easy to use. 
     SUMMARY 
     A power tool attachment saw according to the invention is provide and includes a body plate, a connector section and a plurality of cutting walls. The body plate is a planar body and the connector section positioned on one side of the planar body and adapted for attachment to an oscillating power tool. The plurality of cutting walls are positioned orthogonal to and extend from exterior edges of the planar body to form a material receiving space. The plurality of cutting walls providing a uniform cutting edge about the material receiving space. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings, the same reference numerals are always used for elements with the same function and/or the same structure 
         FIG. 1  is a perspective view of a known oscillating power tool connected to a power tool attachment saw according to the invention; 
         FIG. 2  is a perspective view of an opening provided by a power tool attachment saw of  FIG. 1 ; 
         FIG. 3  is an exploded perspective view of the power tool attachment saw from  FIG. 1 , showing assembly with a known oscillating power tool; 
         FIG. 4  is an exploded perspective view of a power tool attachment saw according to the invention, showing a body plate and a plurality of cutting walls thereof; 
         FIG. 5  is an exploded perspective view of another power tool attachment saw according to the invention, showing a body plate and a plurality of cutting walls thereof; 
         FIG. 6  is a sectional view of a power tool attachment saw according to the invention, showing assembly with a known oscillating power tool; 
         FIG. 7  is a sectional view of a power tool attachment saw according to the invention, showing use with a known oscillating power tool; 
         FIG. 8  is a sectional view of the power tool attachment saw of  FIG. 7 , showing further use with a known oscillating power tool to provide an opening in drywall; 
         FIG. 9  is a perspective view of another power tool attachment saw according to the invention, showing a level; 
         FIG. 10  is a front view of the power tool attachment saw of  FIG. 9 ; 
         FIG. 11  is a perspective view of another power tool attachment saw with a material grasping device according to the invention; 
         FIG. 12  is a sectional view of the power tool attachment saw of  FIG. 9 , showing use with a known oscillating power tool; 
         FIG. 13  is a sectional view of the power tool attachment saw of  FIG. 9 , showing further use with a known oscillating power tool; 
         FIG. 14  is a sectional view of the power tool attachment saw of  FIG. 9 , showing ejection of material held by the material grasping device; 
         FIG. 15  is a perspective view of another power tool attachment saw with a catch according to the invention; 
         FIG. 16  is a rear view of the power tool attachment saw of  FIG. 15 ; 
         FIG. 17  is a sectional view of the power tool attachment saw of  FIG. 15 , showing use with a known oscillating power tool; 
         FIG. 18  is a sectional view of the power tool attachment saw of  FIG. 9 , showing use of the catch; 
         FIG. 19  is a sectional view of the power tool attachment saw of  FIG. 9 , showing further use with a known oscillating power tool; 
         FIG. 20  is a sectional view of the power tool attachment saw of  FIG. 9 , showing even further use with a known oscillating power tool; 
         FIG. 21  is a sectional view of the power tool attachment saw of  FIG. 9 , showing use with a known oscillating power tool to provide an opening in known material; 
         FIG. 22  is a sectional view of the power tool attachment saw of  FIG. 9 , showing ejection of the known material held by the catch; and 
         FIG. 23  is a sectional view of the power tool attachment saw of  FIG. 9 , showing further ejection of material held by the catch. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENT(S) 
     Embodiments of the invention will now be described in greater detail with reference to the drawings. 
     As shown in  FIGS. 1-3 , an improved power tool attachment saw  100  according to the invention is provided and is for use with a known oscillating portable or handheld power tool  200 . 
     In general, the power tool attachment saw  100  is made from steel or another hard material typically used for power tool attachments, such as blades or rasps, depending on the surface being cut, and is coupled to the power tool  200 . 
     As shown in  FIG. 3 , the power tool  200  generally includes a motor (not shown), a spindle  204  and an attachment fastener  210 . The spindle  204  is attached to the motor (not shown) which allows spindle  204  to rapidly rotate back and forth by a narrow angle of oscillation. 
     In the shown embodiment, the spindle  204  generally includes an interface  206  with a plurality of protrusions  208  disposed about the interface  206 . In the shown embodiment, the interface  206  is a planar surface end of the spindle  204 . The spindle  204  further includes a fastener-receiving passageway  114 . As shown, the fastener-receiving passageway  114  is a threaded passageway that is shaped and sized to correspond with the attachment fastener  210 . 
     In the shown embodiment, the attachment fastener  210  generally includes a fastener shaft  212  and a fastener head  214 . The fastener shaft  212  is a threaded fastener with an external male thread that is sized and shaped to correspond with the fastener-receiving passageway  114 , and is detachable from spindle  204 . 
     Generally, the spindle  204  and the attachment fastener  210  are adapted to attach with a number of different tools or tool accessories, one of which is a power tool attachment saw  100  according to the invention. 
     As shown in  FIG. 3 , a power tool attachment saw  100  according to the invention generally includes the following major components: a connector section  110 , a body plate  130 , and a plurality of cutting walls  140 . The connector plate  112  is secured to the body plate  130 , and the cutting walls  140  extend outward from the body plate  130  to provide a cutting tool form that provides repeatable, accurate cuts of uniform dimensions. 
     As shown in  FIG. 3 , the connector section  110  includes a connector plate  112 , a first support arm  120  extending from one end of the connector plate  112 , and a second support arm  125  extending from an opposite end of the connector plate  112 . 
     In an exemplary embodiment, the connector section  110  is made from a single sheet of material, for instance, metal. In the shown embodiment, the connector plate  112 , the first support arm  120 , and the second support arm  125  are formed by bending the sheet of material into a defined configuration, such as the exemplary embodiment described below. While the connector section  110 , in the shown embodiment, is integrally formed by bending a sheet of material, the connector section  110  could also be molded or, in the alternative, the connector section  110  may be formed from individual manufactured pieces that are then secured together using any known joining techniques, such as welding, fastening, or any other method that provides a secure, non-movable connection between the pieces, including adhesion. 
     In the shown embodiment, the connector plate  112  is a planar body that generally includes a fastener-receiving passageway  114 , a fastener-positioning channel  116 , and a plurality of protrusion receiving spaces  118 . In an exemplary embodiment, the fastener-receiving passageway  114  is a circular void extending there through and is positioned proximate to a center of the planar body. The fastener-positioning channel  116  is also a void, but is an elongated void extending through the planar body from one side of the connector plate  112  to the fastener-receiving passageway  114 . The plurality of protrusion receiving spaces  118  are provided and arranged evenly about the fastener-receiving passageway  114 . The fastener-receiving passageway  114  and the protrusion receiving spaces  118  are sized, shaped, and positioned complementary to the fastener shaft  212  and the protrusions  208  of the spindle  204 . 
     The first support arm  120  is a planar body and generally includes a first extension section  122  and a first connector section  124 . In the shown embodiment, the first extension section  122  and the first connector section  124  are planar bodies that are orthogonally positioned to each other. In an exemplary embodiment, the first extension section  122  extends away from the connector plate  112  and, more particularly, at a 90° degree angle. However, one skilled in the art should appreciate that that the angle at which the first support arm  120  extends could be selected based on structural preference of the connector plate  112 . 
     The second support arm  125  is also a planar body and generally includes a second extension section  126  and a second connector section  128 . In the shown embodiment, the second extension section  126  and the second connector section  128  are planar bodies that are orthogonally positioned with respect to each other. In an exemplary embodiment, the second extension section  126  extends away from the connector plate  112  and, more particularly, at a 90° degree angle. However, one skilled in the art should appreciate that that the angle at which the second support arm  125  extends could be selected based on structural preference of the connector plate  112 . 
     One skilled in the art should appreciate that in an alternative embodiment, the first support arm  120  and the second support arm  125  can extend from the connector plate  112  at different angles, including those less than or greater than a 90° degree angle. 
     With reference to  FIGS. 3-5 , the body plate  130  and the cutting walls  140  will be described. 
     As shown, the body plate  130  is a planar body having a length L and a width W. The body plate  130  generally includes a tool receiving passageway  132  extending there through. In the embodiment shown, the tool receiving passageway  132  is positioned proximate to a substantial center of the body plate  130 . The cutting walls  140  are also planar bodies matching the length L or width W of the body plate  130 . The cutting walls  140  extend from edges of the body plate  130  by a depth D 1  that is larger than a thickness T of material to be cut (i.e. drywall), with each cutting wall  140  having a cutting edge  142 . In the shown embodiment, the body plate  130  is rectangular and includes four cutting walls  140  extending orthogonally therefrom. The cutting walls  140  are positioned and secured to outer edges of the body plate  130  at 90° degree angles. The cutting walls  140  may be secured using any known joining techniques, such as welding, fastening, or any other method that provides a secure, non-movable connection between the pieces, including adhesion. As assembled, the body plate  130  and the cutting walls  140  provide a defined form as a rectangular box with a material receiving space  150 . 
     As shown, the body plate  130  and the cutting walls  140  may be formed from a single sheet of material ( FIG. 5 ) or from individual pieces of material ( FIG. 4 ). If made from a moldable material, the body plate  130  and the cutting walls  140  may be integrally formed without any subsequent assembly. 
     In the shown embodiment, the cutting edge  142  is a serrated shaped edge and, more particularly, a hard toothed edge. However, one skilled in the art should appreciate that other known cutting surfaces could be used, such as a blade or burred edge. 
     As shown in  FIG. 3 , the connector section  110  is positioned on the body plate  130 , such that the tool receiving passageway  132  and the fastener-receiving passageway  114  correspond with each other. The first support arm  120  and the second support arm  125  are then secured to the body plate  130  using any known joining techniques, such as welding, fastening, or any other method that provides a secure, non-movable connection between the pieces, including adhesion. The connector plate  112  is positioned above the body plate  130  by a depth D 2  that is larger than a height H of the fastener head  214   
     In an exemplary embodiment of the invention, the power tool attachment saw  100  further includes a level  160 , as shown in  FIGS. 9 and 10 . 
     As shown, the level  160  is any known instrument designed to indicate whether a surface is horizontal (level) and/or vertical (plumb). In the shown embodiment according to the invention, the level  160  is a spirit level and is positioned and secured to the connector section  110 . However, in alternative embodiments, the level  160  could be secured to the body plate  130  or one of the cutting walls  140 . The level  160  may be secured to the connector section  110  or other position using any known joining techniques, such as welding, fastening, or any other method that provides a secure, non-movable connection between the pieces, including adhesion. One skilled in the art would understand that other known measuring devices could be used, including laser line levels, stud finders, and digital tape measures to more accurate position the power tool attachment saw  100 . 
     As shown in  FIGS. 11-14 , in another exemplary embodiment of the invention, the power tool attachment saw  100  includes a material grasping device  170  and an ejection tool passageway  178 . 
     As shown in  FIGS. 11 and 12 , the material grasping device  170  is an elongated clasp that includes a body  172  and a hook  174  positioned and secured at one end thereof. In the shown embodiment, the body  172  is firmly secured to the body plate  130  with the hook  174  extending away therefrom. The body  172  may be secured to the body plate  130  using any known joining techniques, such as welding, fastening, or any other method that provides a secure, non-movable connection between the pieces, including adhesion. As shown, the hook  174  is a curved or an indented end piece that is capable of piercing and snagging material (i.e. drywall). The material grasping device  170  is positioned within the depth D 1  of the material receiving space  150   
     As shown in  FIGS. 11 and 12 , the ejection tool passageway  178  is a through hole extending through the body plate  130  and into the material receiving space  150 . 
     As shown in  FIGS. 15-23 , in another exemplary embodiment of the invention, the power tool attachment saw  100  further includes a catch  180 . 
     In an exemplary embodiment of the invention, the catch  180  generally includes a material grasping device  182  and an ejection device  190 . 
     As shown, the material grasping device  182  includes a body  184 , a stop  186 , and a hook  188  positioned at one end thereof. The stop  186  is an external ridge or rim formed between ends of the body  184 . In particular, the stop  186  is positioned between the body  184  and the hook  188 . 
     The ejection device  190  includes a push body  192 , a spring  198 , and a spring stop  199 . As shown, the push body  192  is a blunt end knob and includes a body receiving passageway  194  and a spring receiving passageway  196 . The body receiving passageway  194  and the spring receiving passageway  196  are both channels that extend through the push body  192  from one end thereof. In the shown embodiment, the body receiving passageway  194  is longer than the spring receiving passageway  196 , however, the spring receiving passageway  196  is wider than the body receiving passageway  194 . In the shown embodiment, the body receiving passageway  194  and the spring receiving passageway  196  are cylindrical channels and correspond in size and shape to the body  184  and the spring  198  respectively. As shown, the spring  198  is a helical spring designed for compression. However, the spring  198  could be any elastic object used to create compression. The spring stop is annular body that is securely positioned along the body plate  130  or the connector section  110  and corresponds with the spring  198 . 
     In the shown embodiment, the body  184  is positioned through a body receiving passageway  131  that extends through the body plate  130  and secured to the ejection device  190 . More particularly, the body  184  is guided through the body receiving passageway  194  and secured to the push body  192 . The spring  198  is positioned between and bias against the push body  192  and the body plate  130  and, more particularly, the spring  198  is positioned against an outer surface of the spring stop  199  and the push body  192  within the spring receiving passageway  196 . The body  184  and may be secured to the push body  192  using any known joining techniques, such as welding, fastening, or any other method that provides a secure, non-movable connection between the pieces, including adhesion. 
     As shown, the hook  188  includes a curved or an indented end piece that is capable of piercing and snagging material (i.e. drywall). The material grasping device  170  is positioned within the depth D 1  of the material receiving space  150   
     As shown in  FIGS. 11 and 12 , ejection tool passageway  178  is a through hole extending through the body plate  130  and into the material receiving space  150 . 
     Now with reference to the Figures, assembly of the power tool attachment saw  100  to the power tool  200  will be described. 
     As shown in  FIG. 3 , the fastener shaft  212  is positioned to the fastener-receiving passageway  114  by guiding the fastener shaft  212  from one side of the connector plate  112  through the fastener-positioning channel  116 . The fastener head  214  is then positioned between the connector plate  112  and the body plate  130 . The interface  206  is then aligned with the plurality of protrusion receiving spaces  118  such that the plurality of protrusions  208  are received by the protrusion receiving spaces  118 . 
     As shown in  FIG. 6 , the fastener shaft  212  is then secured to the fastener-receiving passageway  114  by tightening the fastener shaft  212  using a tightening tool  300  that extends through the tool receiving passageway  132 . 
     Now with reference to  FIGS. 7 and 8 , use of the power tool attachment saw  100  with the power tool  200  will be described. 
     In order to cut an opening, such as a rectangular shaped opening, in a material (i.e. drywall), the use measures and marks corners of the desired opening and then aligns the power tool attachment saw  100  with the first corner and using the power tool attachment saw  100  to cut the opening. Using the level  160 , the cutting walls  140  are position to be horizontal (level) and vertical (plumb) (see also  FIGS. 9 and 10 ). 
     As the power tool  200  oscillates, the power tool attachment saw  100  performs tiny cuts in the material using the cutting edges  142 . Since oscillation is controlled by very small angles (i.e. 1° degree −5° degree), the power tool attachment saw  100  easily cuts through the material, which is then received by the material receiving space  150 . 
     As shown in  FIGS. 11-14 , the material grasping device  170  may be used to grasp the material cut from the opening, wherein the hook  174  pierces the material. As the cutting walls  140  continue to cut, the material slides onto the body  172  to be disposed of. As shown, the material is held in the material receiving space  150  and a user can use a tool (i.e. screwdriver, finger or probe) through the ejection tool passageway  178  to eject the material from the material receiving space  150 . 
     As shown in  FIGS. 15-23 , the catch  180  may be used to grasp the material cut from the opening, wherein the hook  188  pierces the material. As the cutting walls  140  continue to cut, the material slides onto the body  184  to be disposed of. As shown, the material is held in the material receiving space  150  and a user can use the ejection device  190  to eject the material from the material receiving space  150 . 
     Furthermore, the catch  180  can be used to stabilize the cutting walls  140  before cutting. The ejection device  190  can urge the body  184  and hook  188  beyond the depth D 1  of the material receiving space  150  and into the material. The push body  192  is stabilized by the compression of the stop  186  against the body plate  130 . However, when urged, the push body  192  moves the body  184  through the material receiving space  150  and beyond the cutting walls  140 . The stop  186  prevents over extension of the body  184  by abutting the material. The hook  188  then grasps the material and the spring  198  urges the hook  188  toward the body plate  130  to urge the cutting walls  140  against the material, as shown in  FIG. 18 . As the cutting walls  140  continue to cut, the material slides onto the body  184  to be disposed of. 
     To discard, the push body  192  is urged to move the body  184  and the material through the material receiving space  150  and beyond the cutting walls  140 . The user can then extract and discard the material. 
     While various embodiments of the present disclosure have been shown and described, it will be understood that other modifications, substitutions, and alternatives are apparent to one of ordinary skill in the art. Such modifications, substitutions, and alternatives can be made without departing from the spirit and scope of the disclosure.