Abstract:
A method of distressing a board is disclosed. In one embodiment, the method comprises: a) supporting the board on a material support, the board having a substantially planar surface; b) providing a blade having a front surface and a curved back cutting surface, the front surface and the curved back cutting surface intersecting to form a curved tip; c) directing the blade and the substantially planar surface into cutting contact; and d) generating relative movement between the blade and the board to distress a portion of the substantially planar surface; and wherein during step d), the blade is maintained in a fixed orientation relative to the substantially planar surface of the board so that an obtuse mount angle is maintained.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 13/442,966 filed on Apr. 10, 2012. The disclosure of the above application is incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to blades, and more specifically, the present invention relates to blades that are configured to distress a surface of a material. 
       BACKGROUND 
       [0003]    It has become fashionable to subject furniture and other objects/futures or surfaces of walls or flooring of a structure, such as a residence to a design style or technique sometimes referred to as distressing or antiquing. These design styles are intended to “age” the surface of the item or object treated to achieve a unique and/or rustic look. In one aspect of this design style, the surface of the item may be subjected to operations such as sanding, denting, and/or scraping. Typically these types of operations would be performed on furniture or other items, including walls or flooring that are composed of a cellulose-containing material, such as wood and composite board to produce a distressed surface. 
         [0004]    Aspects of a distressed surface can include random irregularities formed in the surface of a material, such as variations relating to depth, width and length of the formed surface irregularity by a tool brought into contact with the material surface, as well as random locations along the surface of the material being scraped. In addition, imperfections are typically desirable, and can occur in response to variations, especially abrupt changes, in mechanical properties of a material having a surface to be distressed. Such changes or variations in mechanical properties could relate to density or hardness of the material. Examples include knots, burls and changes in grain direction, such as commonly associated with wood. The desirable appearance of a material surface variation such as a burl, for example, would typically exhibit discontinuities, sometimes referred to as “chattering”, such as formed by a scraping tool in the material surface both prior to and subsequent to a scraping tool encountering the burl. 
         [0005]    Known constructions of apparatus have been devised in an attempt to produce materials having the desired aspects associated with a distressed material surface. Such constructions, have included sanding heads having discontinuities formed therein, molded heads that are placed in a pressurized contact with a material surface, as well as embossing drums or plates. However, all known apparatus have failed to produce the desired features associated with a distressed material surface. 
         [0006]    A blade that can produce the desired features associated with a distressed material surface in a material would be desirable in the art. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0007]    According to an embodiment, a blade includes a body having a front surface and a curved back cutting surface of between about a 12 inch radius and about an 18 inch radius. The front surface has a mount angle of between about 92 degrees and about 98 degrees relative to a material surface of a material facing the back cutting surface. The back cutting surface has a substrate clearance angle of between about 1 and about 3 degrees relative to the material surface. In response to at least one of the blade and the material surface being brought into cutting contact and moved relative to each other, a resulting portion of the material surface is distressed. 
         [0008]    According to another embodiment, a blade includes a body having a front surface and a curved back cutting surface of about a 15 inch radius. The front surface has a mount angle of about 96 degrees relative to a material surface of a material facing the back cutting surface. The back cutting surface has a substrate clearance angle of about 2 degrees relative to the material surface. In response to at least one of the blade and the material surface being brought into cutting contact and moved relative to each other, a resulting portion of the material surface is distressed. 
         [0009]    According to another embodiment, a method for distressing a surface of a material includes providing a body having a front surface and a curved back cutting surface of between about a 12 inch radius and about an 18 inch radius. The body includes an angle subtended between the front surface and the back cutting surface and being between about 77 degrees and about 85 degrees. The method further includes positioning the front surface between about 92 degrees and about 98 degrees relative to a material surface of a material facing the back cutting surface. The method further includes positioning the back cutting surface between about 1 and about 3 degrees relative to the material surface. The method further includes directing the blade and the material surface into cutting contact, and moving at least one of the blade and the material surface relative to each other. 
         [0010]    In one embodiment, the invention may be a method of distressing a board comprising: a) supporting the board on a material support, the board having a substantially planar surface; b) providing a blade having a front surface and a curved back cutting surface, the front surface and the curved back cutting surface intersecting to form a curved tip; c) directing the blade and the substantially planar surface into cutting contact; and d) moving the board relative to the blade in a feed direction so that a portion of the substantially planar surface becomes distressed by the curved tip of the blade; and wherein during step d), the blade is maintained in a fixed orientation relative to the substantially planar surface of the board so that an obtuse mount angle is maintained between the front surface of the blade and a portion of the substantially planar surface that is upstream of the curved tip. 
         [0011]    In another embodiment, the invention may be a method of distressing a board comprising: a) supporting the board on a material support, the board having a substantially planar surface; b) providing a blade having a front surface and a curved back cutting surface, the front surface and the curved back cutting surface intersecting to form a curved tip; c) directing the blade and the substantially planar surface into cutting contact; and d) moving the blade relative to the board in a scraping direction so that the curved tip of the blade distresses a portion of the substantially planar surface; and wherein during step d), the blade is maintained in a fixed orientation relative to the substantially planar surface of the board so that an obtuse mount angle is maintained between the front surface of the blade and a portion of the substantially planar surface that is downstream of the curved tip. 
         [0012]    Other features and advantages of the present invention will be apparent from the following more detailed description of the preferred embodiment, taken in conjunction with the accompanying drawings which illustrate, by way of example, the principles of the invention. 
         [0013]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    The present invention will become more fully understood from the detailed description and the accompanying drawings, wherein: 
           [0015]      FIG. 1  illustrates a perspective view of an exemplary blade according to an embodiment of the disclosure. 
           [0016]      FIG. 2  illustrates a side view of the blade of  FIG. 1 , according to an embodiment of the disclosure. 
           [0017]      FIG. 3  illustrates a front view of the blade of  FIG. 1 , according to an embodiment of the disclosure. 
       
    
    
       [0018]    Wherever possible, the same reference numbers will be used throughout the drawings to represent the same parts. 
       DETAILED DESCRIPTION 
       [0019]    The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, its application, or uses. 
         [0020]    As used throughout, ranges are used as shorthand for describing each and every value that is within the range. Any value within the range can be selected as the terminus of the range. In addition, all references cited herein are hereby incorporated by referenced in their entireties. In the event of a conflict in a definition in the present disclosure and that of a cited reference, the present disclosure controls. 
         [0021]    Provided is a blade for distressing a surface of a material such as by cutting, which is intended to include scraping. Embodiments of the present disclosure permit fabrication of materials having distressed surfaces not previously available, providing a substantially equal distribution of forces applied to the material surface by the blade. The blade is configured to have an extended life cycle. The blade is configured to be positioned in a substantially fixed orientation relative to the material surface, resulting in an optimum cutting contact with the material surface. It is intended that the term cutting contact include scraping, i.e., that the blade is removing shavings and/or chips from the material surface. 
         [0022]    For purposes of the disclosure, a distressed surface is intended to exhibit a number of characteristics or aspects. For example, a distressed surface or material surface having a distressed appearance or the like is intended to include random irregularities formed in the surface of a material, such as variations relating to depth, width and length of the formed surface irregularity, such as by at least one embodiment of a blade of the present disclosure brought into contact with the material surface, as well as random locations along the surface of the material being distressed. In addition, a distressed surface is intended to include imperfections that may occur in response to variations, especially abrupt changes, in mechanical properties of a material having a surface to be distressed. Such changes or variations in mechanical properties could relate to density or hardness of the material, Examples include knots, burls and changes in grain direction, such as commonly associated with wood, With a distressed surface, the desirable appearance of a material surface variation such as a burl, for example, would typically exhibit discontinuities, sometimes referred to as “chattering”, such as formed by an embodiment of a blade of the present disclosure. The discontinuities would be manifested in the material surface at locations both prior to and subsequent to an embodiment of a blade of the present disclosure encountering the burl. 
         [0023]    It is to be appreciated that another material may include cellulose-containing materials, such as composite board. 
         [0024]    As shown in  FIG. 1 , a blade  10  of the present disclosure includes a body  16  having a front surface  18  and a back cutting surface  20 . Shown opposite back cutting surface  20  is a blade support  28  for blade  10 . A material  12 , such as a board, includes a surface  14  that is positioned facing back cutting surface  20 . As further shown in  FIG. 1 , material support  30  is provided for supporting material  12 . In one embodiment, blade support  28  and material support  30  are interconnected. In use, in response to at least one of blade  10  and material surface  14  being brought into cutting contact and moved relative to each other, a resulting portion of material surface  14  is a distressed surface  32 . For purposes of the present disclosure, the terms cutting surface and cutting contact are also intended to include abrading contact, such as scraping surface  14  of material  12 . 
         [0025]    In one embodiment, blade  10  is constructed of a single, contiguous material, such as a steel, such as M2 tool steel, or other suitable material that maintains an edge, even when subjected to impact, such as between the blade and the material surface. In another embodiment, blade  10  may be formed of several materials joined together, such as by welding, if desired. It is to be understood that the material, as well as the geometry of the blade and the orientation of the blade relative to the surface of a material brought into cutting contact with the blade, contribute to an increase life cycle of the blade of the present disclosure, as compared to other blade constructions. 
         [0026]    As shown in  FIGS. 2-3 , which are not to scale in order to more clearly show and describe features of the present disclosure, blade  10  includes an acute blade angle  34  subtended between front surface  18  and back cutting surface  20 , which surfaces intersect at a point or tip  26 . In one embodiment, blade angle  34  is between about 77 degrees and about 85 degrees, between about 78 degrees and about 85 degrees, between about 79 degrees and about 85 degrees, between about 80 degrees and about 85 degrees, between about 81 degrees and about 85 degrees, between about 82 degrees and about 85 degrees, between about 83 degrees and about 85 degrees, between about 84 degrees and about 85 degrees, between about 77 degrees and about 84 degrees, between about 77 degrees and about 83 degrees, between about 77 degrees and about 82 degrees, between about 77 degrees and about 81 degrees, between about 77 degrees and about 80 degrees, between about 77 degrees and about 79 degrees, between about 77 degrees and about 78 degrees, between about 78 degrees and about 84 degrees, between about 79 degrees and about 83 degrees, between about 80 degrees and about 82 degrees, between about 80 degrees and about 81 degrees, or any suitable range or sub-range thereof. In one embodiment blade angle  34  is about 77 degrees, about 78 degrees, about 79 degrees, about 80 degrees, about 81 degrees, about 82 degrees, about 83 degrees, about 84 degrees, about 85 degrees, or any suitable sub-range thereof. In another embodiment, the magnitude of blade angle  34  can vary within the above referenced ranges, as a function of distance from a central axis  36 . It can be appreciated by virtue of blade angle  34  approaching 90 degrees, versus having an angle of reduced magnitude, that blade  10  contains more material, and is thus a more robust construction. 
         [0027]    As further shown in the figures, in one embodiment, curved back cutting surface  20  defines a profile of between about a 12 inch radius and about an 18 inch radius, between about a 13 inch radius and about an 18 inch radius, between about a 14 inch radius and about an 18 inch radius, between about a 15 inch radius and about an 18 inch radius, between about a 16 inch radius and about an 18 inch radius, between about a 17 inch radius and about an 18 inch radius, between about a 12 inch radius and about a 17 inch radius, between about a 12 inch radius and about a 16 inch radius, between about a 12 inch radius and about a 15 inch radius, between about a 12 inch radius and about a 14 inch radius, between about a 12 inch radius and about a 13 inch radius, between about a 14 inch radius and about a 17 inch radius, between about a 15 inch radius and about a 16 inch radius, or any suitable range or sub-range thereof. In one embodiment curved back cutting surface 20 defines a profile that has about a 12 inch radius, about a 13 inch radius, about a 14 inch radius, about a 15 inch radius, about a 16 inch radius, about a 17 inch radius, about an 18 inch radius, or any suitable sub-range thereof. In other embodiments, curved back cutting surface  20  can define any radius or non-radial (e.g., oval) curve falling within this range. In another embodiment, as shown in  FIG. 3 , the profile of curved back cutting surface  20  is symmetric about central axis  36 , although in another embodiment, curved back cutting surface  20  contains no axis of symmetry. That is, the amount or degree of curvature of curved back cutting surface  20  can vary, if desired. This range of size of curved back cutting surface  20  encompasses different amounts of curved back cutting surface  20 , similarly corresponding to an amount of penetration or depth of a surface of distressed material surface  32  ( FIG. 2 ) from a “pristine” surface  14  of material  12  for a predetermined amount of force directed between blade  10  and surface  14  of material  12 . 
         [0028]    As shown in  FIG. 2 , blade  10  includes an obtuse mount angle  22  subtended between front surface  18  and surface  14  of material  12  facing back cutting surface  20 , which surfaces intersect at point or tip  26 . In one embodiment, blade angle  34  is between about 92 degrees and about 98 degrees, between about 93 degrees and about 98 degrees, between about 94 degrees and about 98 degrees, between about 95 degrees and about 98 degrees, between about 96 degrees and about 98 degrees, between about 97 degrees and about 98 degrees, between about 92 degrees and about 97 degrees, between about 92 degrees and about 96 degrees, between about 92 degrees and about 95 degrees, between about 92 degrees and about 94 degrees, between about 92 degrees and about 93 degrees, between about 93 degrees and about 97 degrees, between about 94 degrees and about 96 degrees, between about 95 degrees and about 96 degrees, or any suitable range or sub-range thereof. In another embodiment, mount angle  22  is about 92 degrees, about 93 degrees, about 94 degrees, about 95 degrees, about 96 degrees, about 97 degrees, about 98 degrees, or any suitable sub-range thereof. Mount angle  22  defines an angular position or orientation of the front surface  18  of blade  10  with respect to surface  14 . 
         [0029]    As shown in  FIG. 2 , blade  10  includes acute substrate clearance angle  24  subtended between back cutting surface  20  and surface  14  of material  12 . In one embodiment, clearance angle  24  is between about 1 degree and about 3 degrees, between about 2 degrees and about 3 degrees, between about 1 degree and about 2 degrees, or any suitable range or sub-range thereof. In another embodiment, substrate clearance angle  24  is about 1 degree, about 2 degrees, about 3 degrees, or any suitable sub-range thereof. Substrate clearance angle  24  encompasses a range of angular separation between back cutting surface  20  and surface  14  of material  12  which has been shown to substantially prevent an accumulation of removed material from surface  14  between surface  14  and back cutting surface  20  sufficient to “clog” the space defining the angular separation. 
         [0030]    Mount angle  22 , blade angle  34 , substrate clearance angle  24  and curved back cutting surface  20  associated with blade  10  and surface  14  of material  12  not only exhibit at least the beneficial results separately, as previously identified, but in combination, also unexpectedly results in optimized operation of the blade during cutting contact between blade  10  and surface  14  of material  12  for forming distressed material surface  32 . For example, in response to blade  10  encountering changes in mechanical properties of material  12 , such as relating to changes or variations in density or hardness of the material  12 , blade  10  exhibits discontinuities, sometimes referred to as “chattering”. That is, the discontinuities are manifested in the material surface at locations both prior to and subsequent to blade  10  encountering such discontinuities. As a result, the blade of the present disclosure, when brought into cutting contact and moved relative to a material surface, such as the surface of a cellulose-containing material, unexpectedly includes a resulting portion of the material surface having a distressed appearance. In one embodiment, surface  14  of material  12  is substantially planar. In another embodiment, surface  14  of material  12  is nonplanar. It is to be understood that blade  10  of the present disclosure can be used to distress nonplanar surfaces if the blade angular relationships or parameters previously discussed, such as mount angle  22  and substrate clearance angle  24  can be maintained. 
         [0031]    In addition, a distressed surface is intended to include imperfections that may occur in response to variations, especially abrupt changes, in mechanical properties of a material having a surface to be distressed. Such changes or variations in mechanical properties could relate to density or hardness of the material. Examples include knots, burls and changes in grain direction, such as commonly associated with wood. With a distressed surface, the desirable appearance of a material surface variation such as a burl, for example, would typically exhibit discontinuities, sometimes referred to as “chattering”, such as formed by an embodiment of a blade of the present disclosure. The discontinuities would be manifested in the material surface at locations both prior to and subsequent to an embodiment of a blade of the present disclosure encountering the burl. 
         [0032]    It is to be understood that since the angular orientations of the blade are relative to the material surface, there is no set orientation of the material relative to horizontal or vertical reference positioning. That is, the blade and material may be positioned such that chips and/or shavings fall away from the material, due to gravity. In one embodiment the blade can be configured to include a “chip breaker”, if desired, as long as the angular relationships between the blade and the material surface, as previously discussed, are maintained. 
         [0033]    It is to he appreciated that the amount of force applied between the blade and the material surface can vary widely, depending upon factors including the density or hardness of the material, the speed of the cutting contact of the blade relative to the speed of the material, as well as other factors. 
         [0034]    While the invention has been described with reference to a preferred embodiment, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.