Patent ID: 12226925

DETAILED DESCRIPTION

This specification taken in conjunction with the drawings sets forth examples of apparatus and methods incorporating one or more aspects of the present inventions in such a manner that any person skilled in the art can make and use the inventions. The examples provide the best modes contemplated for carrying out the inventions, although it should be understood that various modifications can be accomplished within the parameters of the present inventions.

Examples of spacers and of blade cores and of methods of making and using the spacers and the blade cores are described. Depending on what feature or features are incorporated in a given structure or a given method, benefits can be achieved in the structure or the method. For example, spacers that can be inserted into an opening in a blade core by interference fit or sliding fit allow easy assembly of the spacers on a blade core. Additionally, spacers that are positioned on a blade core and configured to engage openings in adjacent blade cores when the blade cores are assembled next to each other provide a more stable assembly, and reduce the possibility variations in blade core positioning. Some spacer configurations can also help to direct airflow for cooling. Discrete spacers can also be used to support other components associated with the assembly. Blade cores using spacers can result in a lighter weight assembly, and an assembly that can allow better cooling of the blade cores during operation. Additionally, blade cores using discrete spacers distributed about the circumference of the blade core improve the weight characteristics and the cooling characteristics of the assembly.

In some configurations of blade cores, improvements can be achieved also in assembly, and in some configurations, interengaging spacers and blade cores provide a more stable and secure final assembly. For example, in a configuration where a single blade core is supported on an arbor and also by spacers positioned on adjacent blade cores, the entire assembly is more secure.

These and other benefits will become more apparent with consideration of the description of the examples herein. However, it should be understood that not all of the benefits or features discussed with respect to a particular example must be incorporated into a blade core, component or method in order to achieve one or more benefits contemplated by these examples. Additionally, it should be understood that features of the examples can be incorporated into a blade core, component or method to achieve some measure of a given benefit even though the benefit may not be optimal compared to other possible configurations. For example, one or more benefits may not be optimized for a given configuration in order to achieve cost reductions, efficiencies or for other reasons known to the person settling on a particular product configuration or method.

Examples of a number of spacer configurations and of blade core configurations and of methods of making and using the spacers and the blade cores are described herein, and some have particular benefits in being used together. However, even though these apparatus and methods are considered together at this point, there is no requirement that they be combined, used together, or that one component or method be used with any other component or method, or combination. Additionally, it will be understood that a given component or method could be combined with other structures or methods not expressly discussed herein while still achieving desirable results.

Blade cores are used as examples of a working tool that can incorporate one or more of the features and derive some of the benefits described herein, and in particular blade cores for grinding and grooving blades. Grinding and grooving blades typically operate on pavement at speeds generating significant heat, and are cooled with water. Grinders and groovers may be improved by providing a lighter weight blade assembly that can possibly be operated at higher speeds and possibly without requiring liquid cooling. However, blade cores and spacers for assemblies other than grinders and groovers can benefit from one or more of the present inventions, including for example without limitation gang blade heads, wood, board and paper cutting assemblies, slitting assemblies and the like.

As used herein, “substantially” and “approximately” shall mean the designated parameter or configuration, plus or minus 10%. However, it should be understood that terminology used for orientation or relative position, such as front, rear, side, left and right, upper and lower, and the like, may be used in the Detailed Description for ease of understanding and reference, and may not be used as exclusive terms for the structures being described and illustrated.

Grinders and groovers, for example and without limitation to application of the present configurations to other working tool assemblies, can benefit from use of one or more of the present configurations. In one example, a grinding and grooving machine100(FIG.1) can be used to prepare or finish a working surface, for example pavement for highways, runways and other surfaces. The machine100includes a frame102supporting an engine104, a hydraulic assembly106and a grinding or grooving head108. Examples of grinding heads are described more fully below. The machine is supported, steered and advanced on the pavement work surface by bogies110, and supported behind by wheel units112. The depth of the grinding or grooving is controlled by a depth control114. The engine104spins the grinding or grooving head108at the desired speed based on the heat limitations of the grinding head, the weight of the grinding head and any other relevant parameters. The bogies pull the machine forward at the desired feed rate or advance rate. A vacuum box116picks up debris from the cutting or grinding and sends it to a separator.

The rotational speed of the grinding head is determined by a combination of the weight of the grinding head and the engine size. The weight of conventional grinding heads limits the blade speed, as does heat generation and cooling limitations.

The grinding or grooving head108can take a number of configurations, which may depend on the size of the machine and the work to be done. In one configuration, the grinding or grooving head can include a shaft and blade assembly200(FIG.2) having a blade shaft202, a plurality of blades204represented schematically inFIG.2and a plurality of solid disc-shaped spacers206, also represented schematically inFIG.2. The blades and spacers are supported on the core of the blade shaft and positioned in registration with one or more keys208. Typically, each blade is separated by a spacer so that blades and spacers alternate with each other, and a grinding or grooving head can have any number of blades, from fewer than 10 to more than 40, depending on the work to be done and the spacing desired for example in a grooving application. The assembly of blades and spacers are placed or stacked against a stop plate210at one end of the blade shaft, and secured in place by a pressure plate212, positioned circumferentially by setscrews214. Upon assembly, the blades and spacers are stacked against the stop plate210and in registration with the key208through one or another of a registration slot216in each blade or a registration slot217in the spacers, the pressure plate212placed against the last disc, and a compression plate218is threaded onto the end of the core of the blade shaft. A plurality of pressure screws220are then threaded into the compression plate and against the pressure plate212in order to place the blades and spacers under compression. The blade head can then be mounted on the machine for operation. All of the blade cores described herein are illustrated as being configured for mounting registration on a blade shaft or arbor such as that illustrated inFIG.2having one or more keys208. However, it is understood that the blade cores, spacers and assemblies described herein can be configured for use on other blade shafts or arbors.

In another example of an assembly for a grinding or grooving head, they had can include a shaft and blade assembly300(FIG.3having a blade shaft302, a plurality of blades304represented schematically inFIG.3and a plurality of solid disc-shaped spacers306, also represented schematically inFIG.3. The blades and spacers are supported on the core of the blade shaft and positioned circumferentially relative to each other by being positioned and placed over a plurality, in the present example 4, of threaded rods308. As with the assembly illustrated inFIG.2, each blade is separated by a spacer so that blades and spacers alternate with each other, and a grinding or grooving head can have any number of blades, depending on the design of the machine. The assembly of blades and spacers are placed or stacked against a first plate310on the threaded rods308and terminated with a second plate312, and the assembly secured in compression by respective nuts314. The blade head can then be mounted on the machine for operation.

Any of the blade core and spacer assemblies (with working tips or materials applied to the parameters of the blade cores) described herein can be assembled into a blade head for use with an arbor or blade shaft such as that described and illustrated with respect toFIG.2. Such blade cores would include registration slots to accommodate keys on the blade shaft. Alternatively, or additionally, any of the blade cores described herein can be configured with working tips or materials to be mounted on an arbor or blade shaft such as that described and illustrated with respect toFIG.3along with any of the spacers described herein to form a working head. Either of the working heads can be placed on a grinding or grooving machine, for example one such as that described with respect toFIG.1. Alternatively, blade cores with working surfaces and spacers as described herein can be assembled into blade heads for other applications, for example for cutting wood, board, paper or slitting applications. Examples of blade cores and spacers will be described herein in the context of blade cores for grinders and groovers, for example for use in the assemblies illustrated and described with respect toFIGS.1-3, and modifications can be made to adapt the blade cores for other applications, for example by modifying the blade cores for how they are supported on a drive structure.

Blade and spacer assemblies for applications identified herein can include anywhere from two or three blades up to as many as 40 or more in the assembly. Blade assemblies for grinders and groovers can have 10 or more blades all the way up to 40 or more, and are arranged to be coaxial with one another, as illustrated inFIG.4, for being supported and controlled by a blade shaft or arbor. Other examples of blade assemblies described herein will show a plurality of blade cores, for example two blade cores, three blade cores or four blade cores, with the understanding that the desired blade assembly will have the desired number of blades for the application, additional blades for a given assembly being omitted from the illustrations for clarity. Configuration of additional blade cores will be a repetition of those described in a given example.

In one example of a blade assembly for groovers and grinders, a blade assembly400(FIG.4) includes registration slots216and217for proper positioning on a blade shaft such as that illustrated inFIG.2with one or more keys208. The blade assembly400is configured to be arranged on a blade shaft200with the registration slots216, in the example illustrated, and each blade core (no working tips or working materials are illustrated on any of the blade cores illustrated herein, but it is understood that final working configurations include working tips or working materials as needed) includes an inner wall402defining an opening having an inside diameter suitable for reliably placing the blade core on the blade shaft to be supported during normal operation. Blade cores for grinders and groovers have openings with inside diameters ranging between 3 inches up to 10 or 12 inches or more, for example because of the size of the blade shaft designed to carry and drive the number of blades and spacers in a blade head, and to optimize the blade core configurations for such blade heads. The walls defining circular openings in all of the blade cores described herein for the blade shafts illustrated inFIG.2, or if configured for the blade shaft illustrated inFIG.3, are typically all concentric and have the same general inside diameter, excluding any cutouts or cavities described herein, for example the registration slots216and217. Other blade shaft opening wall configurations can be used for blade cores, as desired, including those configurations described herein for accommodating spacers, for example.

The blade core extends from the wall402defining the opening for the blade shaft to a perimeter404of the blade core. The perimeter is generally circular but for straight sections406made linear for easier attachment of working segments, and for gullets408between straight sections. Other perimeter configurations can be used for blade cores, as desired, for example as a function of the work to be done with the blade assembly.

Generally, the blade cores described herein all will have the same blade shaft opening, registration slots, and perimeter configurations as described for the blade cores in the blade assembly400illustrated inFIG.4, unless otherwise indicated. Elements assigned the same reference numeral herein will have the same structure and function as described herein, unless otherwise indicated.

At least one blade core in a blade assembly, and possibly every other blade core in a blade assembly, and in the configurations illustrated herein every blade core in a blade assembly, includes at least one spacer supported by a blade core. The spacer or spacers can have any one or more of the configurations described herein. In one example, including any of the examples in the foregoing two sentences, the at least one spacer is formed from a material other than a working material, where working material is a material applied to the perimeter area of the blade core for working a workpiece, examples of which include carbide tips and diamond matrix materials. As used herein, “supported by a blade core” means the spacer is limited or restricted in movement in a direction parallel to a plane of the blade core, including for example by engagement between at least a portion of the spacer and a surface on or in the blade core. In some examples, the spacer is supported by a blade in a direction parallel to a radial direction relative to the blade core, by an interaction between the spacer and the blade core. In the examples described herein, the interaction includes physical interaction, including for example engagement with a sidewall of the blade core, and magnetic interaction, but it is understood that other types of interactions between a spacer and a blade core limiting or restricting movement parallel to a plane of a blade core are included in the phrase “supported by a blade core”. In the examples described and illustrated herein, the spacers are supported by a blade core through openings or cavities formed in the blade core, for example by openings extending outward from the blade shaft opening or extending inward from the blade core perimeter, or by openings formed in the blade core between the shaft opening and the perimeter and formed by a closed wall, or by cavities in a blade core formed partly into but not all the way through a blade core. In some of the examples described herein, the spacers are supported by the blade core and only a blade core and not by the blade shaft directly but only by a blade shaft indirectly through a blade core. Additionally, some examples of the spacers described herein have no working function with respect to a work surface such as pavement, concrete, wood or other works, and serve only a spacing function with respect to a blade core and its adjacent blade core or to adjacent blade cores. In other examples, the spacers may have only a spacing function and a fluid flow function to direct fluid based on surface configurations of the spacer. Also in the examples described and illustrated herein, the spacers are steel, aluminum, or may be thermoplastic, thermoset plastic, engineered plastic, UHMW plastic or similar materials other than working materials. Also in some of the examples described herein, the spacers are formed from a material other than a working material and are supported only by a blade core or a plurality of blade cores.

A spacer can be used with a number of blade core configurations for blade assemblies, including those described herein. In one example, a spacer500can be used in a blade core assembly502(FIGS.5-8). The spacer500can be used alone or in combination with identical spacers or with other spacers described herein. In the present example, the spacer includes a first body portion504extending in different directions in a plane, in the present example parallel to a plane of the blade core506in which the spacer is supported, which for example may be mutually perpendicular directions508and510(FIG.5). The first body portion has a maximum height or thickness in a direction perpendicular to directions508and510an amount that is selected to be equal to the desired spacing between adjacent blades506and512(FIG.5) in a final assembly. In the example illustrated, the first body portion includes a bevel surface514extending from an inside face516to an outside face518(FIG.7), both of which are flat in the present example, and the thickness is defined by the spacing between the inside and outside faces. In the present example, the first body portion has a substantially circular or disc geometry, but the first body portion can take any number of geometric configurations providing the desired thickness and extension in different directions.

The spacer500also includes a second body portion520extending away from the first body portion, for example in a third direction perpendicular to the first body portion504, in the present example perpendicular to the directions508and510. The second body portion is configured to contact a portion of the blade core506between oppositely-facing surfaces of the blade core. In the present example, the second body portion passes into and through a circular opening in the blade core, and contacts at least part of a circular wall forming the circular opening in the blade core. As illustrated, the second body portion520is a right circular cylinder, but the second body portion can take other geometric configurations that can also permit the second body portion to contact a wall of an opening in the blade core, for example so that the blade core can support the spacer, such as in a direction parallel to a plane of the blade core. Also in the present example, the second body portion is solid, but need not be, and the first and second body portions have the same geometric profile in cross section, but can be otherwise. (All examples of spacers described herein with respect toFIGS.5-60are configured so that the respective blade cores can support the spacer in at least one direction parallel to a plane of the blade core.) In the example of a cylindrical second body portion and a circular opening in the blade core, the blade core supports the spacer in a radial direction relative to a center of the blade core, and in all 360° in a plane of the blade core. For a noncircular opening in a blade core, it is possible that the spacer would not be supported by contact at all 360° directions in a plane parallel to the blade core. The second body portion has a thickness approximately the same as a thickness of the blade core506, taking into account tolerances and the like, and may have a thickness that accommodates easy positioning of the spacer in the opening in the blade core while still allowing the first body portion504to maintain the desired spacing between the blade core506and the next adjacent blade core which the face518of the spacer will contact when the blades are assembled together.

The spacer500having first and second body portions can be held in position in an opening in the blade core506by any of a number of means, including interference fit, adhesive, welding, mechanical means or other means for reliably positioning the spacer in the opening in the blade core506, and the first and second body portions are the only body portions in the spacer. An interference fit can be complete around the entire perimeter of a 360° contact, or may be partial with one or more points or one or more surfaces on the second body portion contacting respective surfaces in the opening in the blade core. The fit can be a close fit or no interference fit in an alternative configurations, and may be held in place by any of the other configurations described herein. Alternatively or additionally, the spacer500is held in place in an opening in the blade core by a third body portion522. In the present example, the third body portion522extends in different directions parallel to a plane of the blade core, and in one example forming a circular body portion extending in mutually perpendicular directions524and526(FIG.6). The third body portion may have other geometries. The third body portion522includes a bevel surface528, but may have other edge geometries. The third body portion includes an inside face530and outside face532, both of which are flat as illustrated, facing in opposite directions in the illustrated example, and the thickness is defined by the spacing between the inside and outside faces. In the present example, the third body portion has a height or thickness in a direction perpendicular to the directions524and526an amount that is selected to be equal to the desired spacing between adjacent blades506and512(FIG.5) in a final assembly. The spacer500with the first, second and third body portions is formed monolithic, but can be formed from two or more parts. In one example when formed of two or more parts, one part with a second body portion fitting into an opening in the blade core can have a clearance fit or less than completely interference fit, and application of an additional body portion may produce an interference fit or a more complete interference fit. In another example (not shown), a third body portion may have a maximum outside dimension less than or equal to a maximum outside dimension of the second body portion and have a height or width providing the desired spacing between a blade core supporting the spacer and an adjacent blade core. In such an example, the third body portion provides little if any securement function holding the spacer in place on the blade core, with the remaining or all of the securement function for the spacer being provided by the second body portion and/or any additional structures or materials, such as fastenings, adhesives, or the like, along with lateral support provided by the first body portion.

In the present example, four spacers500are distributed equidistant from each other about the circumference of the blade core506. Other numbers of spacers and/or distributions are possible. Additionally in the illustrated example, all of the spacers on a given blade core face in the same direction, but their orientation can be alternated or varied as desired. Generally, the arrangement and orientation of spacers on each blade core in an assembly will be consistent from one blade core to the next, for example so that stacking of blade cores into a blade assembly will produce the desired blade spacing and distribution of spacers about the circumference of the blade assembly. In the present example, the blade core512includes the same number of spacers500A (spacers identical to spacers500) as the blade core506, in the present example four spacers, and the spacers are oriented on the blade core512the same way the spacers500are oriented on the blade core506. When the blade cores are assembled to form a blade assembly, the blade core506and the blade core512are shifted about their central axis, for example shifted relative to each other on a blade shaft, so that the spacers500A are shifted 45° relative to the spacers500. This allows eight spacers to contribute to spacing of adjacent blades while having only four spacers on each blade core. Other numbers of spacers and distributions can be used.

It is noted that a spacer500supported in an opening in the blade core506will be spaced apart from a blade core512as illustrated inFIG.5based on a spacing defined by the third body portion522, as well as the thicknesses of third body portions on any other spacers supported on the blade core506. Similarly, the spacing between the blade core506and blade core512will also be determined by the first body portions504of spacers500A placed in the blade core512, as illustrated inFIG.6, which is a rear elevation view of the assembly shown inFIG.5. The spacers500A are positioned in the blade core512the same as the spacers500are positioned in the blade core506, so that the outside faces518of the spacers face in the same direction. Alternatively, spacers can be configured to face in opposite directions alternately about a given blade core. Additionally, as illustrated inFIGS.5and6, the blade core512is shifted 45° so that the spacers in the blade core506on the one hand and the spacers500A in the blade core512on the other hand are shifted relative to each other. Such a configuration allows for spacers on each blade core to provide spacing between adjacent blade cores at a different locations, for example eight locations in the illustrated example. Other combinations are possible.

The blade core506and spacers500, or the blade core512and spacers500A, can form an assembly of a blade core and spacers, and a plurality of blade core and spacer assemblies can be combined to form a blade assembly or blade head such as may be used on a groover or a grinder in the present illustrations. The blade core506and spacers500will be described, but it is understood that the other blades in a blade assembly will be identical or sufficiently similar to provide the desired blade makeup and spacing, and in the example illustrated inFIG.5, adjacent blade cores are shifted 45° relative to each other so that the spacers in one blade core contact the adjacent blade core intermediate the spacers on the adjacent blade core.

The illustrated blade core506includes registration key slots216and217, the registration key slots216being a pair diametrically opposite each other, and the registration slots217being a pair position diametrically opposite each other. The registration slots are formed extending radially outward from the blade shaft opening402. The blade core506includes at least three and preferably four or more circular openings (not shown) for receiving respective spacers500. In the example of four openings, the four openings are positioned equidistant from each other, namely 90° apart on the blade core positioned intermediate the blade shaft opening402and the perimeter404. In the present example, the four or more openings are positioned on an annulus (not shown) that coincides or is aligned with the fasteners220in the compression plate218(FIG.2), or an annulus defined by such fasteners (if threating of the compression plate onto the blade shaft does not result in a particular fastener being aligned with a particular opening in the blade core). In an example of more than four openings, the openings are positioned equidistant from adjacent ones of the openings on the compression annulus, though they need not be.

In an assembly of a blade core and spacers, the blade core506includes in the illustrated example four spacers500evenly distributed about the blade core, approximately intermediate the shaft opening402and the perimeter404, while other radial positions are possible. More or fewer spacers can be distributed about the blade core, and the number may be a function of the size of the first body portion and the size of the third body portion, if a third body portion is included. The thickness of the first body portion and the thickness of the third body portion are preferably identical so that they produce the desired spacing between adjacent blade cores. The height or thickness of the second body portion is preferably as close as possible to the thickness of the blade core so that the float of the spacer in the circular opening in the blade core is as small as possible.

Each spacer is inserted into the respective circular opening in the blade core by pressing the outside face518so that at least a portion of the inside face530on the third body portion flexes, compresses or bends sufficient to pass the third body portion through the opening to the opposite side of the blade core506. The inside face516of the first body portion contacts the facing surface of the blade core, and the inside face530of the third body portion faces the adjacent surface of the blade core. The outside faces518and532face in opposite directions and are substantially planar and parallel to the plane of the blade core when the spacer is in position. The remaining spacers are also inserted in like manner. While it is possible that a given blade core can have the spacers inserted from either side, consistent assembly helps to properly orient the blade on the blade shaft in final assembly, especially if blade rotation is intended to be in one direction. The spacers can be held in place by the existing inter-engagement, but other means can alternatively or additionally be used to maintain the spacers in place. The second blade core512and others are assembled in like manner, and the blades with working elements are assembled on a blade shaft, with adjacent blades shifted 45° if desired. If adjacent blades are not shifted, the spacing between adjacent blades would be twice the thickness of the first body portion, which would also typically be twice the thickness of the third body portion.

In another example of a spacer that is configured to be supported by a blade core, a spacer900(FIGS.9-14) includes a first body portion902and a second body portion904. The second body portion is configured to be supported by a blade core. The spacer can be used alone or with additional identical spacers on a blade core, or in combination with other spacers described herein. The first body portion902extends in a plane906, in the present example parallel to a plane of a blade core such as the plane of a blade core950. The first body portion has a height or thickness in a direction perpendicular to the plane906an amount that is selected to be equal to the desired spacing between adjacent blades, for example that using blade core950and the adjacent blade core952(FIGS.9-10). The first body portion includes an outer surface908, which in the present example is a flat surface extending parallel to the plane906, and an inner surface910facing in a direction opposite that of the outer surface908and parallel to the plane906.

The first body portion has a planar geometry that is deltoid, having three sides. The deltoid geometry includes a first junction912between adjacent sides that has a first radius of curvature, and second and third junctions914that have a smaller radius of curvature than the first junction, but the radius of curvature of the second and third junctions are substantially the same.

The second body portion904of the spacer extends away from, and as illustrated perpendicular to, the first body portion in a direction away from the inner surface910. The second body portion is configured to contact a portion of the blade core950between oppositely-facing surfaces of the blade core. In the present example, the second body portion passes into and through an opening in the form of a slot954in the blade core950. The second body portion contacts at least part of one or more walls in the blade core forming the slot954. In the illustrated example, the second body portion904is a right circular cylinder, but the second body portion can take other geometric configurations that can also permit the second body portion to contact one or more walls of the slot in the blade core, for example so that the blade core can support the spacer, such as in a direction parallel to a plane of the blade core. In another example, a portion of the second body portion904adjacent the inner surface910is circular, for example a top portion of the second body portion, and opposite sides on each side of the circular portion may be straight, for example parallel or not. Straight sides can help to limit pivoting of the spacer900when positioned in a slot of a blade core, for example a slot having sides complementary to the adjacent surfaces of the second body portion, for example straight sides.

The first and second body portions902and904are formed monolithic and solid, but can be otherwise. With the spacer900, the first and second body portions do not have the same geometries, but in the illustrated example, the lower portion of the second body portion and the lower portion of the first body portion forming the junction912are partly circular and have the same radius of curvature.

In the example of the right circular cylindrical second body portion and the spacer positioned in the slot954in a blade core, the blade core supports the spacer in a direction parallel to the blade core, and when the blade is spinning, centripetal force pushes the spacer against the closed end of the slot954. As a result, the end of the slot supports the spacer900in a radial direction relative to a center of the blade core. The slot954also supports the spacer in other directions, but when the blade core is stationary, no structure supports the spacer in the radially inward direction toward the center of the blade core. If the spacer is held in place at the closed end of the slot954by mechanical means, adhesive, or otherwise, the spacer would be supported in the blade core at those locations.

In another example of the second body portion for the spacer900, the second body portion includes first and second straight walls, in one example extending parallel to each other, extending on spaced apart sides of the second body portion. The straight sidewalls can be used to help position the spacer900in a respective opening in a blade core supporting the spacer. For example, as described below, an opening in a blade core having spaced apart straight sidewalls can help to position a spacer having a surface configuration in the second body portion complementary to one or more portions of the wall in the blade core opening.

The second body portion904in the spacer900has a thickness approximately the same as a thickness of the blade core950, taking into account tolerances and the like. The second body portion may have a thickness that accommodates easy positioning of the spacer in the slot954while still allowing the first body portion902to maintain the desired spacing between the blade core950and the next adjacent blade core952when the blade cores are placed next to each other. The lateral dimensions of the second body portion can also be selected for the desired positioning of the spacer in the slot. In one configuration, the second body portion can have a diameter providing a clearance fit in the slot954, so that the spacer can be moved easily in the slot. In another configuration, the second body portion can have a diameter providing a close fit, for example so that the spacer does not fall out of the slot without applying a force other than gravity. In a further example, the second body portion can have a diameter providing an interference fit, requiring a force to insert the spacer in the slot. Where the second body portion is other than a right circular cylinder, for example some other cylindrical shape, similar considerations can be applied to provide the desired fit in an opening in a blade core.

The spacer900having first and second body portions can be held in position in an opening in the blade core950(and similarly with respect to any other blade core of the same or similar configuration, such as blade core552) by a number of means, including interference fit, adhesive, welding, mechanical means or other means for reliably positioning the spacer in the opening in the blade core. Alternatively or additionally, the spacer900is held in place relative to the plane of the blade core in the opening in the blade core by a third body portion916. In the present example, the third body portion916extends transversely perpendicular to the right circular cylinder of the second body portion904, parallel to the plane906. The third body portion in combination with the first body portion forms a groove between them, the spacing for which is determined by the height or thickness of the second body portion. The third body portion can take a number of geometric configurations, for example circular, oval, polygon, or other shapes, but in the present example the third body portion has a deltoid geometry. Also in the present example, the third body portion has a deltoid geometry substantially the same as that of the first body portion, and is a mirror image of the first body portion parallel to the plane906. The third body portion includes an inside face918an outside phase920, facing in opposite directions, both of which are substantially flat in the illustrated configuration. The third body portion has a height or thickness in a direction perpendicular to the plane906an amount that is selected to be equal to the desired spacing between adjacent blades, for example950and952(FIG.9) in a final assembly.

One or more spacers900can be used with a blade core, such as a blade core for grinders and groovers, having respective non-circular openings in the core for supporting a respective spacer. In one example, the blade core950includes a wall402defining the arbor opening in the blade core, and a plurality of registration slots216and217. The blade core950has an arbor opening of at least 3 inches up to about 12 inches or more for being supported on the blade arbor for a grinding or grooving head. In the configuration shown inFIG.9, the blade core includes four registration slots. The blade core950further includes an additional slot, namely slot954, which is noncircular (seeFIG.9A), and in the illustrated configurations deeper than the registration slots. In the present example, the blade core950includes a plurality of noncircular slots954, each of which are identical, and only one will be described in detail. Four noncircular slots are illustrated, arranged uniformly about the arbor opening, each extending radially outward therefrom, but more or less than four can be incorporated into the blade core950. In the present example, each noncircular opening includes two spaced apart straight sidewalls956and958extending outward from the arbor opening. In one example, the straight sidewalls extend parallel to each other, and in another example they converge outwardly, or they may diverge. The two sidewalls can be other than straight, but straight sidewalls help to guide the insertion of the spacer900. The two straight sidewalls terminate at an end wall960, in the present example a semicircular wall terminating the slot954. Even though the semicircular wall is partially circular, the shape of the entire opening is noncircular, or in other words the slot954has portions that make the slot a noncircular opening, namely the straight sidewalls. The depth of the slot954can be selected so as to position the respective spacer at the desired location relative to the shaft opening and the outer perimeter, and also to ensure the strength and integrity of the blade core is maintained, and in the present example the slot954is deeper than, or extends a greater distance outward from the blade shaft opening402, the registration slots216and217.

The configuration of the spacer900and the blade core950can be used to assemble a blade core and spacer assembly, and multiple blade core and spacer assemblies can be used to form a blade assembly or blade head. In the present example, first and second blade cores950and952are described and illustrated, with the understanding that this plurality of blade cores can form a blade core and spacer assembly, and such assemblies can include more than two such blade core and spacer assemblies. For example, blade heads for grinders and groovers can have as many as 40 blades or more. The second blade core952and the assembly of the blade core and associated spacers are identical to the first blade core950, and they are arranged on a blade shaft with one rotated 45° relative to the other. Therefore, only the assembly of the blade core950and associated spacers900is described.

A blade core and spacer assembly980(FIGS.9-10) includes the blade core950and one or more spacers900, in the present example four spacers. Four slots954are distributed evenly around the shaft opening402and extend generally radially outward from a center of the blade core. Each spacer900is positioned in a respective slot954in the same manner. Each spacer is oriented so that the larger junction912is closer to the center of the blade core, and the two smaller junctions914are farthest from the center of the blade core. In that orientation, the side containing the smaller junctions914form the widest portion of the spacer, so that the surface area of the spacer increases as the spacer extends radially outward. Other orientations are possible, but the illustrated orientation presents a wider surface area closer to the working perimeter of the blade core.

When the spacer is in position, the first and third body portions sandwich the portion of the blade core between the two body portions, and the relative spacing between the two body portions and the thickness of the blade core at the slot954help to determine the ability of the spacer to move in the slot. If the spacing between the two body portions (or the height or thickness of the second body portion) is less than the blade core thickness, the dimensions provide an interference fit for the spacer on the blade core. If the spacing is approximately the same as the blade core thickness, the spacer has a close fit, and if greater has a clearance fit. Even if the spacer has a clearance fit, the spacer is maintained in the slot554once the assembly is placed on a blade arbor since the blade arbor prevents the spacer from coming out of the slot954. During operation, the centripetal force produced during rotation apply than outward force on the spacer pushing it toward the closing wall960of the slot954. The semicircular closing wall960of the slot954forms a surface complementary to the upper circular surface of the second body portion. Because the first and third body portions of the spacer are mirror images, the assembly has the same configuration whether the first body portion is on one side of the blade core or the other.

In the example where all of the spacers on the blade core550are the same, with the same orientation relative to the blade core, the assembly can be repeated with multiple blade cores and their respective spacers. Multiple blade core and spacer assemblies can be combined into a blade head. In the present example illustrated inFIGS.9and10, the second blade core952is identical to the blade core and spacer assembly950and the two are positioned on a blade shaft shifted rotationally 45° relative to each other, while still having registration openings216aligning with each other. With the shift, each set of four spacers on the respective blade cores provide spacing functions of eight spacers for the two blade core assemblies facing each other. A different alignment configuration, spacer distribution, spacer density and spacer configuration can be used with these or similar blade cores for producing the desired assembly. In one example of a different configuration of the blade assembly, the blade cores are not shifted 45° relative to each other, in which case the spacing between the blades is the sum of the spacing provided by each of the spacer body portions in contact with each other, for example the third body portion on one blade core and the first body portion on the other blade core.

Another spacer that can be used with the blade core950(FIG.9) is a spacer1700(FIGS.15-22). The spacer is identical to the spacer900except that a wedge is removed from a center of the top portion of the deltoid structures of the first and third body portions. The spacer1700has a V-shape with the first body portion1702having diverging legs1704and1706joined together by a rounded body portion1708, which is coincident with a circular second body portion1710. The third body portion1712is a mirror image of the first body portion on a side of the second body portion opposite the first body portion. The spacer1700is otherwise identical to the spacer900, and can be configured in the same way with the same function, and can be used with the blade core950or a plurality of such blade cores in the same way that the spacer900is used.

A further example of a blade core for a grinding or grooving machine includes one or more openings that are noncircular. In one example, a blade core1750(FIG.15) includes a wall defining a central opening402for a blade shaft and registration slots216and217for positioning the blade core on a blade shaft. The blade core has an arbor opening of at least 3 inches up to about 12 inches or more for being supported on the blade shaft for grinding or grooving. The blade core includes a noncircular opening, and in the present example a plurality of noncircular openings1752(FIGS.15-16) for receiving and supporting a respective spacer. In the illustrated example, there are four identical noncircular openings1752, and only one will be described. In the present example, the opening1752has the same geometric profile as spacer1700, and the dimensions of the profile are slightly greater than the dimensions of the spacer1700to allow either the first or third body portion to enter and pass through the opening1752from one side of the blade core to the other side. Where the dimensions of the first body portion and the second body portion of the spacer1700are identical, either of the first and third body portions can be pushed into the opening for positioning the spacer in the opening. Where the dimensions of one of the first and third body portions is greater than a dimension of the opening1752, only the other of the body portions can be used to position the spacer in the opening.

The opening1752in the present example is an inverted V-shape relative to the center of the blade core, and includes walls defining first and second legs1754and1756converging toward the perimeter of the blade core at a junction1758. The legs1754and1756and the junction1758generally conform to the legs1704and1706and the junction1708of the spacer1700. The spacer1752is positioned radially on the blade core so that the center of the junction1758is at an approximate center of the blade core between the shaft opening402and the perimeter404. The opening can be positioned at any desired location on the blade core.

In another example of a blade core and spacer assembly, a blade core and spacer assembly1780(FIG.15) includes the blade core1750and the desired number of spacers1700, and multiple such blade core and spacer assemblies can be combined adjacent each other to form a blade head. A second adjacent blade core1760includes the same spacers1700in four respective openings, and when assembled on a blade shaft, the second blade core and spacer assembly is rotated 45° relative to the first blade core and spacer assembly1780, so that the spacers1700on the second blade core1760contact the first blade core1750on a portion of the surface intermediate adjacent spacers1700on the first blade core. The first and second blade core and spacer assemblies together can form a blade assembly or blade head, and for a grinding or grooving assembly, additional blade assemblies can be included, for example up to 40 or more.

A spacer1700is positioned on the blade core by first inverting the spacer relative to the central axis of the blade core so that the first and second legs1704and1706point to the shaft opening and the first body portion (or the third body portion) lines up with the opening1752. The spacer is then pressed into the opening until the first body portion extends to the opposite side of the blade core and the second body portion1710is substantially lined up with the blade core. The spacer is then pivoted 180° so that the first and second legs on the first body portion and the first and second legs on the third body portion point outward toward the perimeter. The second body portion is then positioned between the outer edge1762having a partial circular curvature and an inner edge1764also having a partial circular curvature. The spacer is then supported by the blade core to limit movement of the spacer in the plain of the blade core. Additionally, the first and second legs1704and1706of the first and third body portions sandwich the adjacent portion of the blade core, to thereby limit axial movement of the spacer relative to the blade core.

With the spacers positioned on the blade core as illustrated inFIG.15, the widest portion of the spacer and the largest lateral coverage of the spacer across the adjacent surface of the blade core is closer to the perimeter than the rounded body portion1708. This position of the spacer increases the effect of the spacing provided by the first and third body portions closer to the perimeter, where the blades are working on the subject material.

In another example of a spacer that can be used with blade cores and supported by a blade core, a spacer2500(FIGS.23-31) is configured to be supported by a blade core, and in one configuration contact a portion of the blade core intermediate oppositely facing sides of the blade core, for example a wall of an opening formed in the blade core. The spacer2500includes a first body portion2502to serve as a spacer element between a blade core on which the spacer2500is supported and a next adjacent blade core. The first body portion is that portion of the spacer that extends along and outward from an adjacent surface of a blade core. The spacer2500also includes a second body portion2504extending away from the first body portion, for example substantially perpendicular to the first body portion. In the present illustrated example, the second body portion2504extends away from the first body portion a distance substantially equal to a thickness of a blade core on which the spacer2500is supported. The second body portion is defined by the thickness corresponding to the thickness of the blade core on which it is supported.

The spacer2500can be supported in a blade core, for example blade core2600(FIGS.23and28-30), by a number of means. For example, the spacer can be supported in the blade core in an opening (not shown) that precisely fits the second body portion, for example in an interference fit or a close fit. Alternatively, the spacer can be supported in another opening such as that described with respect toFIGS.23-23Bthat permits securement of the spacer in the opening mechanically, by welding, adhesive or other means for reliably holding the spacer in position.

In the present example, the spacer2500includes a third body portion2506(FIGS.24-27) extending outward from the second body portion2504opposite the first body portion. The third body portion includes a wall that can help to position the spacer2500on the blade core, and also includes a structure to serve as a spacer element between the blade core on which the spacer is supported and a next adjacent blade core (different from the next adjacent blade core closest to the first body portion). While they can be different from each other, the first and third body portions are mirror images of each other about a plane bisecting the second body portion parallel to the blade core on which the spacer is supported. Therefore, the first body portion will be described in more detail.

The first body portion2502includes a first inner wall2508extending along an upper portion of the first body portion from a first end2510of the spacer to a second end2512and extends outward from the adjacent surface of the second body portion. The first inner wall extends outward substantially perpendicular to the second body portion, and is configured to extend substantially parallel to an adjacent surface of the blade core supporting the spacer. The height of the wall, or the recess of the second body portion is substantially the same between the first and second ends. The second body portion2506includes a first inner wall2514extending along the upper portion of the first body portion from the first end2510to the second end, and the height is substantially the same between the two ends. The second inner wall extends substantially parallel to the first inner wall, and to an adjacent surface of the blade core. The first inner walls of the first and second body portions form a channel2516extending between the first and second ends and has a channel bottom wall2517, which is the upper, outwardly-exposed surface of the second body portion. The channel is configured to receive the exposed wall of an opening in the blade core so that the spacer can be positioned in the opening and supported by the blade core, which may be by either or all of contact with the channel bottom wall2517or being sandwiched between the first walls2508and2514. Portions of the first and third body portions sandwich a portion of the blade core to help position the spacer laterally relative to the blade core. The spacing of the first walls of the first and third body portions can provide an interference fit, in which case the spacer can be reliably supported on the blade core during normal operation, especially with the centripetal force developed during rotation of the blade core. The spacing of the first walls can also provide a close fit, making it easier to position the spacer in the opening, but possibly allowing part of the spacer to disengage from the blade core, for example by an unintended impact. The closeness of the fit will help to determine how easy it is to position the spacer and how easy it is to dislodge it before a final assembly is complete. The spacing can also provide a clearance fit, in which case the spacer may be held in place by other means, such as a template, fixing structure or other temporary positioning device, or more permanent means such as welding, adhesive, or the like. Interference fit, close fit and clearance fit may apply equally over the entire length of the channel2516, or the channel may have one fit configuration at one or several locations and other fit configurations at other locations of the channel, thereby providing some flexibility over the form of the fit between the spacer and the blade core.

In the present example, the first and third body portions include converging walls2518and2520(FIGS.24,25and27), respectively, at an approximate middle portion of the groove to assist in aligning the spacer with the blade core wall in the opening in which the spacer is to be positioned. The converging walls can extend along the groove2516as far as desired.

The first body portion includes an outwardly-facing wall2522, facing opposite the first wall2508. The outwardly-facing wall in the present example extends entirely around a perimeter of the first body portion, but other configurations can have the outwardly-facing wall arranged as segments around the perimeter of the first body portion or in selected locations of the first body portion. The thickness of the first body portion or the spacing between the first wall2508and the oppositely-facing wall2522directly opposite the first wall defines the desired spacing between adjacent blade cores. The oppositely facing wall2522is configured to contact the facing surface of an adjacent blade core. In one configuration, the oppositely facing wall2522can be a continuous flat surface top to bottom and side to side, forming the outermost surface of the first body portion, but in the illustrated example, the oppositely facing wall and all of the spacer is interrupted or discontinuous by way of an opening2524extending completely through the spacer. The opening2524can take any number of configurations, but in the present example has a geometry similar to the overall geometry of the spacer. Because of the existence of the opening2524, the oppositely-facing wall2522forms a perimeter circuit around the first body portion.

In the spacer2500, rather than the oppositely-facing wall2522forming the outermost surface of the first body portion, the first body portion also includes a boss or projection2526extending outwardly from the first body portion. The boss or projection2526forms a shoulder or perimeter wall2528. The shoulder or perimeter wall2528in the present example extends around the entire portion of the first body portion, but may be formed in segments, bumps, dimples, tabs or other structures forming an equivalent or analogous structure to a shoulder or perimeter wall. The shoulder or perimeter wall is configured to engage an opening in an adjacent blade core having a geometry substantially matching that of the shoulder or perimeter wall. Engaging an opening in an adjacent blade core can be by interference fit, close fit or clearance fit, providing a desired amount of support between the two structures. With an interference or close fit, and in some respects a clearance fit, the spacer2500supported by its respective blade core can help to support the adjacent blade core, and vice versa.

In the illustrated configuration, the boss2526includes a substantially flat surface2530. As described more fully below, the flat surface2530can bear up against a complementary flat surface on an adjacent spacer two blade cores away extending into the same opening in the adjacent blade core. Good contact between complementary flat surfaces can help to put an entire blade assembly under a compressive load to help strengthen the blade assembly and stabilize the blades in a blade head. Alternatively or additionally, the flat surface2530can define an outer boundary for the first body portion2502of the spacer to define the spacing between the blade core2600and the next adjacent blade core in the direction of the flat surface2530. In one configuration, the spacing between such adjacent blade cores is represented by the spacing or thickness between the inside surface2508and the flat surface2530when the flat surface contacts the facing surface of such adjacent blade core. In a second configuration, the spacing between such adjacent blade cores is represented by twice the spacing or thickness between the inside surface2508and the flat surface2530when the flat surface contacts a corresponding flat surface on the boss or projection2532on a third body portion of a spacer supported by the next adjacent blade core. In the second configuration, the spacers on adjacent blade cores are not shifted 45°, and as a result, the spacers on adjacent blade cores are aligned.

In the present example of the spacer2500, the third body portion includes an identical mirror image boss or projection2532and shoulder or perimeter wall2534.

The spacer illustrated at2500has a deltoid geometry in front and rear elevation, and has substantially straight sides2536and2538(FIG.26) meeting at the apex or junction in the area of the converging walls2518and2520. In the other direction, they terminate at the first and second ends2510and2512, respectively, to join the bottom2540. The bottom2540has a concave curvature to accommodate a convex curvature in an opening in the blade core. The opening2524through the spacer converges to the center of the second body portion from the outside. The opening provides a measure of airflow through the blade cores and weight reduction in the overall assembly compared to a solid spacer configuration. Additionally, the geometry and/or the positioning of the spacer2500can be selected so as to provide a desired airflow in the spacing between adjacent blade cores, and/or between adjacent blade cores, for example through openings formed in a blade core and/or through the spacers. In one example, one side of the deltoid can be angled differently than another side of the deltoid to thereby affect fluid flow along the blade core and around the spacer.

Another example of a blade core for a grinding or grooving machine having one or more openings that are noncircular is illustrated inFIGS.23-23B and28-31. In this example, the blade core2600includes a wall defining a central opening402for a blade shaft and registration slots216and217for positioning the blade core on a blade shaft. The blade core has an arbor opening of at least 3 inches up to about 12 inches or more for being supported on the blade shaft for grinding or grooving. The blade core includes a noncircular opening, and in the present example a plurality of noncircular openings2602for receiving and supporting a respective spacer. In the example illustrated, there are four identical noncircular openings2602, and only one will be described. In the present example, the opening2602has the same geometric profile as the spacer2500, but the dimensions of the profile are different than the dimensions of the spacer2500. As illustrated, the different dimensions allow the spacer to fit into a portion of the opening2602radially inward, and then allow the spacer to be moved radially outward to contact and engage a wall of the opening in a radially outward portion of the opening. The size of the spacer relative to the size of the opening allows either the first or third body portions to enter and pass through the opening2602from one side of the blade core to the other side. The geometric profiles can be different while the size of the spacer can be selected so as to permit the desired movement of the spacer in a respective opening in the blade core.

In the present example, each opening2602has a deltoid configuration with first and second walls2604and2606, shown for convenience on an adjacent blade2608inFIG.23B, that converge toward each other to a junction2610outward in the direction of the perimeter404. The walls are substantially straight outside the junctions2610and respective junctions with an opposite wall2612, and are configured to fit into the groove2516in the respective spacer so that the bottom of the groove contacts respective portions of the exposed surfaces of the first and second walls2604and2606, in other words the bottom of the groove contacts respective portions of the wall of an opening between the oppositely-facing surfaces of the blade core. The bottom of the groove can be configured to contact all or portions of the adjacent wall of the opening. The openings are substantially centered radially between the arbor opening402and the perimeter404.

In one example of the blade core2600(not shown), the blade core2600can have one or more openings having the configuration and size shown in the drawings, and a plurality of such openings can be distributed substantially uniformly about the blade core, or otherwise. In one configuration, the blade core2600and have openings for receiving respective spacers only of the same configuration and size, and spacers2500or other suitable spacers are positioned in one or more of respective openings2602for providing desired spacing between the blade core2600and one or more adjacent blade cores such as a blade core2600having only openings substantially identical to opening2602. In such a blade core and spacer assembly, the spacing between adjacent blade cores would be the spacing defined by the first or third body portion between the groove and the outermost face2530or2532in the situation where a spacer contacts and adjacent blade core surface intermediate adjacent openings2602(adjacent blade cores being shifted 45° with respect to each other), or would be the spacing defined by the spacer2500between the oppositely-facing side surfaces2530and2532on the first and third body portions (the spacer of one blade core contacting the adjacent spacer on the adjacent blade core).

Alternatively or additionally, the blade core2600can include an additional opening or a plurality of additional openings, each of which is different from the opening2602. In the example illustrated inFIGS.23-23B and28-31, each blade core includes a secondary opening2614different from at least one characteristic of the openings2602, which in the present example of the blade core2600may be termed primary openings2602. The at least one characteristic of the openings2602in the present example is size, namely the surface area or dimensions of the openings2614. In the illustrated configuration, the openings2614are smaller than the openings2602, and specifically the opening size or the side profile is smaller in that the distance around the perimeter is less than that for the openings2602. The shapes or geometry of the openings are substantially identical, and have a deltoid shape. In other configurations of the opening, the opening can be other than deltoid, the opening can be deltoid but having a different shape (triangular, oval, circular, or other shapes, such as where the spacer2500is deltoid but the bosses2526and2532are segmented and form only a triangular, oval, circular or other shape perimeter), or the opening can have a more simple (circular) or more complex geometry. The secondary openings2614can be larger than the openings2602, and the spacers2500can be configured so that the bosses on the first and third body portions engage such larger openings, but spacers for being supported in openings2602and for engaging larger openings2614in adjacent blade cores may be more costly to manufacture.

The secondary openings2614can be positioned at any number of locations on the blade core2600. As illustrated, the secondary openings2614are positioned intermediate the openings2602, and in equal number. They are positioned radially approximately equidistant between the blade shaft opening402and the perimeter404.

In a further example of a blade core and spacer assembly, a blade core and spacer assembly2650(FIGS.23-23B and28-31) includes the blade core2600(with or without secondary openings) and the desired number of spacers2500, and multiple such blade core and spacer assemblies can be combined adjacent each other to form a blade head. A second adjacent blade core such as2608and/or further blade cores2652and2654can be assembled with respective sets of spacers2500supported by the blade core and assembled on a blade shaft to form a blade head. In the illustrated example, the second blade core2608includes the same spacers2500in four respective openings, the third blade core2652includes the same spacers2500in four respective openings, and the fourth blade core2654includes the same spacers2500in four respective openings. Each spacer is positioned in the same way on its respective blade core, with the first or third body portion of a spacer inserted into a respective opening2602, at the radially-inward portion of the opening. When the channel2516aligns with the blade core, the spacer is maneuvered so that the blade core opening wall facing the channel injures the channel between the converging walls2518and2520and into the channel between the walls2508and2514. In one configuration, the adjacent wall of the blade core opening will seat against the bottom wall2517of the channel, for example along the length of the entire surface of the bottom wall. The walls2508and2514of the channel can be configured to provide an interference fit, close fit or clearance fit over all or a portion of the channel with the adjacent surfaces of the blade core, as desired.

When assembled on a blade shaft, the second blade core2608is rotated 45° relative to the first blade core2600, the third blade core2652also rotated 45° relative to the first blade core, and the fourth blade core in the same orientation as the first blade core2600, but rotated 45° relative to the third blade core2652. In such configuration, spacers on a given blade core are supported by such blade core so that the spacer cannot move much in the direction of the blade perimeter, because of the blade in the channel, and in the present example engagement of the blade core with a respective channel2516in the spacer2500helps to support the spacer laterally or axially of the blade core. Spacers on a given blade core, for example on the blade core2600in the illustrated example, are configured so that the bosses2526fit into secondary openings2614on the adjacent blade core2608, and so that the bosses2532on the third body portion fit into secondary openings2614on the additional blade core2652. The adjacent side surfaces on the blade core2608contact the walls2522on the first body portion of the respective spacer, and the adjacent side surfaces on the blade core2652contact the walls on the third body portion of the respective spacer. The bosses on the spacer can be configured to provide an interference fit, close fit or clearance fit, a close fit providing reliable assembly and support of the blade cores with the spacers. Additionally, the spacers2500on the second blade core2608have the bosses2532on the third body portions extending into respective ones of secondary openings2614on the blade core2600, and likewise with such spacers and an adjacent blade core on a side of the second blade core2608opposite the blade core2600. Additionally, the blade core2652includes respective spacers similarly engaging the same secondary openings2614as are engaged by the bosses on the third body portion of the spacers2600on the second blade core2608. The heights of the bosses2526and2532on the first and third body portions of the spacers are approximately, and preferably identical to approximately one half or between 40%-50% of the width of the blade cores in the blade head assembly so that a given blade core is engaged by respective spacers on adjacent blade cores on each side of the given blade core. For example, for a 2.67 mm blade thickness, the height of each boss2526and2532is about 1.30 mm, which provides a gap of approximately 0.07 mm between adjacent spacers2500on adjacent blade cores, for example2600and2654when the boss2532on the third body portion of one spacer is adjacent the boss2526on the first body portion of the adjacent spacer. The 0.07 mm gap allows for tolerance in the assembly, and a measure of compression if there is any spacing between a blade core and an adjacent spacer body portion.FIG.30illustrates a first spacer2500in the upper portion of the Figure and a second spacer2500in a lower portion of the Figure, the two spacers in the assembly being positioned 45° apart in the assembly.

The blade cores2600and2608together can form a blade assembly or blade head, and for a grooving or grinding assembly, additional blade assemblies can be included, for example up to 40 or more. The blade cores can be mounted on a blade shaft assembly such as that illustrated inFIG.2, and respective adapter plates placed over respective ends of the blade assembly. An adapter plate, such as that shown inFIG.70, is used to adapt an end blade core and its spacers to a pressure plate such as a pressure plate212on the shaft assembly to accommodate the un-mated spacers on the end blade core. A first adapter plate is placed against the baseplate210(FIG.2) and then a first blade core and spacer assembly is positioned so that respective spacers are accommodated by recesses or cavities in the adapter plate and a registration slot216placed on the key208. A next blade core and spacer assembly is then positioned on the first blade core and spacer assembly, but rotated 45°, so that a second registration key217registers with the key208, and first bosses2526engage secondary openings in the second blade core, and bosses2532on the third body portion of a respective spacer fit into corresponding secondary openings in the first blade core and spacer assembly. Subsequent blade core and spacer assemblies are rotated and position in like manner until all of the blade core and spacer assemblies are placed on the blade shaft. Another adapter plate is placed on the last blade core and spacer assembly, with recesses or cavities fitting over corresponding spacers and against the last blade core, so that pressure applied by the pressure plate212produces compression of the entire blade assembly between the baseplate210and the pressure plate212. Such a blade assembly is more stable and secure when pressure is applied to the blade assembly by the pressure plate. The resulting compression stabilizes each blade core in the area of each of the spacers, which is also in areas adjacent the perimeter where the working surfaces are applied.

In an assembly of blades such as those described with respect toFIGS.23-31, the spacing between adjacent blades is determined by whether or not each adjacent blade core includes respective spacers, whether adjacent blade cores are rotated relative to each other, and whether or not each blade core includes secondary openings.

Another example of a spacer configured to be supported by a blade core includes spacer3300(FIGS.32-37) having a first body portion3302and a second body portion3304. The second body portion is configured to be supported by a blade core3400(FIGS.32and34). The spacer can be used alone or with additional identical spacers on a blade core, or in combination with other spacers described herein. The first body portion3302extends in a plane substantially parallel to a blade core by which it is supported, and in the illustrated example is substantially flat and circular. The first body portion has a height or thickness in a direction perpendicular to a plane containing the first body portion an amount that is selected to be equal to the desired spacing between adjacent blade cores. The first body portion includes an outer surface3306to contact an adjacent blade core, and an inner surface3308for contacting an adjacent surface of the blade core supporting the spacer3300, and the inner and outer surfaces face in opposite directions.

The second body portion3304extends away from the interface3308of the first body portion. The second body portion is configured to contact a portion of the blade core3400between oppositely-facing surfaces of the blade core through an opening3402(FIG.32) through the blade core intermediate the blade shaft opening402and the perimeter404. The height or thickness of the second body portion3304is substantially the same as the thickness of the blade core3400. The geometry of the second body portion3304is substantially a rounded rectangle having curving or convex sidewalls and curving or convex end walls. The convex end walls are dimensioned to fit between curved sidewalls3404and3406in the blade core3400. The walls of the second body portion contacts at least part of one or more walls in the blade core, so that the blade core can support the spacer at least in a direction parallel to a plane of the blade core, for example radially.

The first and second body portions3302and3304are formed monolithic and solid, but can be otherwise, and in the present example includes an opening3310for receiving a tool to pivot the spacer3300. As illustrated, the opening3310is a hexagonal opening, which can receive a hexagonal wrench, for example. With the spacer3300, the first and second body portions do not have the same geometries, but the first body portion can be noncircular. The spacer3300can be held in position by a number of means, including interference fit, adhesive, welding, mechanical means or other means for reliably positioning the spacer in the opening3402in the blade core. Alternatively or additionally, the spacer3300is held in place relative to the plane of the blade core in the opening in the blade core by a third body portion3312. In the present example the third body portion3312extends outward from the opening3310and includes convex sidewalls and convex end walls slightly smaller than the walls of the opening3402in the blade core so that the third body portion can fit easily through the opening until the inner wall3308of the first body portion contacts the adjacent side of the blade core. The third body portion forms a pair of oppositely-facing grooves3314between wings3316and3318of the third body portion and respective opposite surfaces on the inside face3308. The depth or width of the grooves is approximately the same as a thickness of the blade core3400. The third body portion can take a number of geometric shapes or configurations, but in the present example the geometry of the third body portion is selected so as to fit into an opening in a blade core, for example blade core3400, and to help secure the spacer in position on the blade core together with the first body portion when the spacer is pivoted at least partly in the opening3402. In the example illustrated, the spacer is best held in position when the spacer is pivoted 90°. The third body portion has a height or thickness in a direction perpendicular to the plane of the blade an amount that is selected to be equal to the desired spacing between adjacent blades, and in the present example identical to the height or thickness of the first body portion3302. As illustrated, the width of the grooves3314and therefore the blade core is greater than the width or height of the first and second body portions.

The configuration of the spacer3300and the blade core3400can be used to assemble a blade core and spacer assembly, and multiple blade core and spacer assemblies can be used to form a blade assembly or blade head. For example, blade heads for grinders and groovers can have as many as 40 blades or more, such as the blade core and spacer assembly represented inFIGS.32-37, and adjacent blade core and spacer assemblies can be positioned so that the spacers on one blade core are offset 45° from the spacers on adjacent blade core. As illustrated, each blade core has for openings3402, but can have fewer or more, with respective spacers3300. The openings3402are distributed evenly about the blade core, and each opening is positioned approximately intermediate the blade shaft opening402and the perimeter404, and in one example on an annulus coinciding with the circular arrangement of the fasteners of the pressure plate. Each spacer is positioned on the blade by inserting the third body portion3312into the respective opening3402until the second body portion3304is coplanar with the blade core. The spacer is then pivoted 90°, for example manually or with a tool, so that the first and third body portions sandwich the blade core, and adjacent portions of the blade core are positioned in the grooves3314. The assembly of blade core and spacers can be repeated as desired to produce a blade assembly (blade core and spacer assemblies with working surfaces applied), and multiple blade core and spacer assemblies can be combined into a blade head. With adjacent blade core and spacer assemblies shifted 45° relative to each other, each set of four spacers in a respective blade core provides spacing functions of eight spacers for two blade core assemblies facing each other, and the spacing between adjacent blade cores is determined by the height or thicknesses of the first and third body portions. Different alignments can be used to produce different spacings.

In another example of a spacer for use with a blade core, for example a blade core for use in a grinding or grooving head, a magnetic spacer3900(FIGS.38-39) includes a first body portion3902. As illustrated, the first body portion is a right circular cylindrical disc, but can take any number of configurations. The magnet includes a circular perimeter surface3904, a first flat surface3906and a second flat surface3908, wherein one of the flat surfaces is placed against an adjacent surface of a blade core3950. In one configuration, the surface of the blade core3950is uniformly flat, and the magnetic spacer3900is placed on the flat surface. In another configuration (not shown), the blade core includes a circular or other geometric depression corresponding to the geometry of the magnetic spacer3900, and the spacer is placed in the depression. In the configuration of a flat surface, the blade core supports the spacer by a magnetic interaction between the magnet and the magnetic field produced by the magnet and the adjacent surface of the metal blade core. In the configuration of a blade core having a depression, the blade core supports the spacer both by a magnetic interaction and by mechanical interaction. In the present example, the spacer has only a first body portion, but in another example (not shown) the spacer can include a second body portion for extending into an opening formed in the blade core for supporting the spacer. The spacer alternatively or additionally can be held in position on a blade core by any number of other means, including those described herein.

The magnetic spacer can be used alone or in combination with identical spacers or with other spacers described herein. In the example illustrated, four spacers3900are distributed equidistant from adjacent ones of each other about the circumference of the blade core3950. Other blade cores including adjacent blade cores making up the blade assembly include corresponding spacers, and in the example of magnetic spacers, the blades can be shifted 45° so that spacers on adjacent blade cores alternate positions, or each blade core can have magnetic spacers3900positioned on both sides of the same blade core at the same angular positions, and an adjacent blade core identically configured shifted 45° so that each blade core is supported by eight spacers. The spacers can be positioned as desired relative to the blade shaft opening402and the perimeter404, but in the present example the spacers are positioned on an annulus substantially coincident with an annulus of the fasteners on the pressure plate. Multiple blade core and spacer assemblies can be combined on a blade shaft, for example that illustrated and described with respect toFIG.2, to form a blade head, for example for a grinder or groover.

In another example of a spacer for a rotary working blade core, a spacer4200can be configured to engage a portion of a blade core, for example a blade core for a grooving or grinding head, that can be used on a grooving or grinding machine. The spacer4200includes a first body portion4202that extends in a first direction, for example along an axis4204from a first side4206to a second side4208. The distance in the first direction, for example from the first side4206to the second side4208of the first body portion can be used to define a spacing between adjacent blade cores, for example a first blade core4250and4252(FIGS.40-41). In the present configuration, the thickness defines the maximum spacing between adjacent blade cores. The first body portion is mounted on or supported by the first blade core, and the axial distance or thickness of the first body portion is used as a spacer between the first blade core4250and the second blade core4252, and likewise with other blade cores on which the spacer4200is used. The first body portion includes respective surfaces on the first and second sides4206and4208facing respective surfaces4254and4256(FIG.41), and in the illustrated example, all of the respective surfaces are used to contact the adjacent blade core surfaces for providing the spacing defined by the thickness of the first body portion. In another configuration, the surfaces can include respective bosses, bumps or dimples, for example, that would contact the adjacent blade core surfaces, and the spacing defined by the first body portion would be the spacing defined by the maximum thickness between the outermost surfaces of such bosses, bumps or dimples.

The spacer4200first body portion extends outwardly to a perimeter surface4210, which in the illustrated example is a circular circumferential surface, but can take other geometries. The first body portion extends in a direction parallel to a plane of the blade core in which the spacer is supported, and the first body portion in the illustrated configuration is a substantially right circular cylinder, though it can take other configurations.

The spacer4200also includes a second body portion4212extending adjacent the first body portion and along the axis4204. In the present example, the first body portion and the second body portion are concentric about the axis. The second body portion forms a blade engagement structure for limiting movement of the spacer, for example the first body portion, in a direction parallel to the plane of the blade core. The second body portion is configured to contact a portion of the blade core4250between oppositely-facing surfaces of the blade core. In the present example, the second body portion extends into an opening, in the illustrated example a circular opening4258in the blade core4250, but the geometry of the second body portion and the opening in the blade core can be other than circular. In many cases, the profile or geometry of the second body portion and the profile or geometry of the opening in the blade core are the same or substantially the same. In the illustrated example, the second body portion is a right circular cylinder, but can take other geometric configurations that can also permit the second body portion to contact a wall of an opening in the blade core, for example so that the blade core can support the spacer, such as in a direction parallel to a plane of the blade core. Also in the present example, the second body portion is solid, but need not be, and the first and second body portions have the same geometric profile in cross section, but can be otherwise. In the example of a cylindrical second body portion4212and a circular opening4258in the blade core, the blade core supports the spacer in a radial direction relative to a center of the blade core, and in all 360° in a plane of the blade core. For a noncircular opening in a blade core, it is possible that the spacer would not be supported by contact at all 360° directions in a plane parallel to the blade core. The second body portion4212has a thickness approximately the same as a thickness of the blade core4250, taking into account tolerances and the like, and may have a thickness that accommodates easy positioning of the spacer in the opening in the blade core while still allowing the first body portion4202to maintain the desired spacing between the blade core4250and the adjacent blade core4252which the side4206will contact when the blade cores are assembled to be adjacent each other.

The spacer4200having first and second body portions can be held in position in an opening in the blade core4250by any number of means, including any of those discussed herein, including interference fit, adhesive, welding, mechanical means or other means for reliably positioning the spacer in the opening4258in the blade core4250, and the first and second body portions are the only body portions forming the spacer. Additionally or alternatively, the spacer4200includes an additional or secondary second body portion4216. The additional second body portion forms a blade engagement structure for limiting movement of the spacer, including the first body portion, in a direction in the plain of the blade core, for example blade core4250, and the blade core4252. In the present example, the first body portion4202and the primary second body portion4212and the additional second body portion4216are concentric about the axis4204. The additional second body portion is configured to contact a portion of the blade core4252between oppositely-facing surfaces of the blade core. The additional second body portion generally has the identical structure and function as the primary second body portion4212, but may be otherwise. In the present example, the additional second body portion extends into an opening, in the illustrated example a circular opening4260(FIG.41) in the adjacent blade core4252, but the geometry of the additional second body portion and the opening in the adjacent blade core can be other than circular. In many cases, the profile or geometry of the additional second body portion and the profile or geometry of the opening in the additional blade core are the same or substantially the same. In the illustrated example, the additional second body portion is a mirror image of the primary second body portion4212, in the illustrated example a right circular cylinder extending away from the first body portion4202in a direction opposite the primary second body portion4212. Alternatively, the additional second body portion can take other geometric configurations that can also permit the additional second body portion to contact a wall of an opening in the adjacent blade core, for example so that the adjacent blade core can support the spacer4200such as in a direction parallel to a plane of the blade core. Also in the present example, the additional second body portion is solid, but need not be, and the geometry of the additional second body portion can be different than the geometry of the first body portion and the primary second body portion.

In the example of a cylindrical additional second body portion4216and a circular opening4260in the blade core, the blade core supports the spacer in a radial direction relative to a center of the blade core, and in all 360° a plane of the blade core4252. For a noncircular opening in a blade core supporting the additional second body portion, it is possible that the spacer would not be supported by contact at all 360° directions in a plane parallel to the blade core. The additional second body portion has a thickness approximately the same as a thickness of the blade core4252, taking into account tolerances and the like, and may have a thickness that accommodates easy positioning of the spacer and the blade core with respect to each other while still allowing the first body portion4202to maintain the desired spacing between the blade core4250and the blade core4252. As can be seen in the present configuration, the spacer has a first body portion and two second body portions, or in other words the second body portion extends on both sides of the first body portion. In the illustrated configuration, the primary and secondary second body portions can be considered to be continuous from one side of the first body portion to the other side of the first body portion, extending therethrough, or the primary and secondary second body portions can be considered to be spaced apart by the first body portion. Both of the primary and secondary second body portions are supported by respective blade cores, and supported in a direction parallel to a plane of a blade core. The spacer is not directly supported by the blade shaft, but instead supported directly by a blade core or blade cores. The spacer engages a blade core or adjacent blade cores by having the second body portion or second body portions extend into an opening in a blade core or openings in adjacent blade cores.

In the examples of the spacers4200described herein, the second body portion or the primary and secondary second body portions can have a depth or thickness in the axial direction approximately equal to a thickness of a blade core into which a second body portion is inserted. In an alternative, the depth or thickness in the axial direction of the second body portion or the primary and secondary second body portions is approximately half or less than approximately half of the thickness of a blade core, so that an opening in a blade core can receive the second body portions of two spacers, one from each side of the blade core.

In the examples of the spacers4200described herein, one or more spacers can be supported on a blade core4250and/or adjacent blade cores4250and4252. In the illustrated example, four spacers4200are distributed equidistant from each other about the blade core4250. Other numbers of spacers and/or distributions are possible. Additionally in the illustrated example, all of the spacers on a given blade core face in the same direction, for example so that the first body portions4202contact the side4256of the blade core4250and the second body portion4212extends into the opening4258in the blade core. However, the orientation of one or more spacers can be altered or varied as desired. Generally, the arrangement and orientation of spacers on each blade core in an assembly will be consistent from one blade core to the next, for example so that stacking of blade cores into a blade assembly will produce the desired blade spacing and distribution of spacers about the blade assembly. In the present example, the blade core4250includes the same number of spacers (4) as the blade core4252, and when a blade core is assembled adjacent another blade core, the blade core is shifted about its central axis, for example shifted relative to each other on a blade shaft, so that the spacers on the blade core4250are shifted 45° relative to the spacers on the blade core4252. In such a configuration, the blade cores4250and4252are separated from each other by four spacers, but they can have fewer or more than four spacers between them. In another configuration, the depth or thickness of the second body portions are approximately half or less than half the thickness of a blade core, and each blade core is assembled with eight spacers so that the blade core4250and the blade core4252are separated by eight spacers. In one example, the blade core4250is assembled with four equally spaced apart spacers, and the blade core4252is assembled with four equally spaced apart spacers and the blade cores positioned adjacent each other but shifted 45° so that the four spacers on each blade core will engage an adjacent opening in the other blade core.

The blade core4250and spacers4200and the blade core4252and spacers4200can be assembled to form a blade core and spacer assemblies, and a plurality of blade cores and spacer assemblies can be combined to form a blade assembly or blade head, such as may be used on a groover or a grinder in the present illustrations. The blade core4250and spacers4200will be described, but it is understood that the other blades in a blade assembly will be identical or sufficiently similar to provide the desired blade makeup and spacing, and in the example illustrated inFIG.40, adjacent blade cores are shifted 45° relative to each other so that the spacers in one blade core contact the adjacent blade core intermediate the spacers on the adjacent blade core. The blade core4250includes in the illustrated example 4 spacers4200evenly distributed about the blade core, approximately intermediate the shaft opening402and the perimeter404, while other radial positions are possible. The openings and the spacers in the present configuration generally coincide with an annulus defined by the fasteners in a pressure plate in a blade head in which the blade core and spacer assembly is assembled. More or fewer spacers can be distributed about the blade core, and the number may be a function of the size of the first and second body portions.

Each spacer is inserted into a respective circular opening in the blade core4250by pressing on the side of the spacer opposite the second body portion4212so that the second body portion4212fits into the opening4258in the blade core. The wall4208in the first body portion contacts the facing surface of the blade core4250, and the second body portion4212is supported in the opening in the blade core. Additional spacers are also inserted in like manner, for example from the same side of the blade core. The number and distribution of spacers can be selected as desired, including with the configuration described herein. For example, each blade core can have for evenly distributed spacers and the adjacent blade cores4250and4252are spaced apart by four spacers, for example where the second body portions are approximately the same height or thickness as a thickness of the blade core. Alternatively, the height or thickness of the second body portions can be approximately half or less than the thickness of the blade core, and adjacent blade cores can be separated by eight spacers, or the number of spacers selected by the user. Other combinations are also possible. The spacers can be held in place by the existing inter-engagement, but other means can alternatively or additionally be used to maintain the spacers in place. The second blade core4252and others are assembled in like manner, and the blades with working elements are assembled on a blade shaft, with adjacent blades shifted 45° if desired. The actual spacing between adjacent blade cores will be determined by the selection of spacers, their orientations relative to spacers in adjacent blade cores, and whether or not each spacer includes a first body portion and a single second body portion, or a first body portion and primary and secondary second body portions. A plurality of blade cores can then be assembled on to a blade shaft such as that described with respect toFIG.2and used on a machine such as that described with respect toFIG.1.

In an alternative configuration of a spacer that can be used with blade cores and supported by a blade core and/or by a rod or shaft, a spacer4300(FIG.43A) is identical in all respects to the spacer4200in each of the examples described with respect to the spacer4200(for example a single second body portion or primary and secondary second body portions), except as otherwise described herein. The spacer4300has a first body portion4302identical to the first body portion4202except that the first body portion includes beveled surfaces4304and4306, and a center opening4308, in the present example centered about an axis of rotation (not shown) the same as the axis4204, so that the first body portion and the opening are concentric. The opening is formed by a cylindrical wall4310centered on a central axis. The spacer may but need not include a second body portion4312extending axially away from the first body portion4302, concentric with the central axis. The spacer need not, but in the present example the spacer4300includes an additional or secondary second body portion that can be partially visualized at4314. The primary and secondary second body portions4312and4314are substantially mirror images of each other, and have the same functions as the second body portions4212in4216. The primary and secondary second body portions4312and4314are also hollow from the opening4308defined by the cylindrical wall4310. In the present example, the second body portions4312include outer and inner beveled surfaces4316and4318, for example to assist in assembling the spacer into a blade core, and assembling adjacent blade core and spacer assemblies together on a blade shaft. The spacer4300can be substituted for the spacer4200in all respects, in the manner described herein with respect to the spacer4200. The spacer can be used on blade core assemblies for use on the blade shaft described and illustrated inFIG.2. In the example where the spacer4300has only a first body portion4302and omits one or more of the second body portions4312and4314, the spacer can be supported by an indexing rod or other support (not shown) extending through the opening4308between two or more blade cores and associated openings4308in similar spacers on adjacent blade cores to maintain the radial positions of the spacers4300. Alternatively, the spacer4300can be assembled with blade cores and used in blade core assemblies to be assembled on a blade shaft such as that described with respect toFIG.3, with threaded rods extending through corresponding openings in sets of four spacers4300in each of the blade cores. In the example where the spacer4300has only a first body portion4302and omits one or both of the second body portions4312and4314, the spacer is supported on a respective threaded rod (FIG.3) and extends between adjacent blade cores with a thickness selected according to the desired spacing between adjacent blade cores. In the example where the spacer4300includes one or both of the second body portions4312and4314, each spacer is supported on a respective blade core, and on an adjacent blade core in the example of primary and secondary second body portions, and the spacers are also supported on the respective threaded rods.

In another example of a spacer for a rotary working blade core, a spacer4700(FIGS.44-51) can be configured to engage a portion of a blade core, for example a blade core for a grooving or grinding head, that can be used on a grooving or grinding machine such as that illustrated inFIG.1. The spacer4700includes a first body portion4702that extends outward along an axis from a first side4704to a second side4706. The distance along the axis, for example from the first side4704to the second side4706of the first body portion can be used to define a spacing between adjacent blade cores, for example a first blade core4800and a second blade core4802(FIGS.44-46). In the present configuration, the thickness defines the maximum spacing between adjacent blade cores. The first body portion is mounted on or supported by the first blade core, and the axial distance or thickness of the first body portion is used as a spacer between the first blade core4800and the second blade core4802, and likewise with other blade cores on which the spacer4700is used. The first body portion include respective surfaces on the first and second sides4704and4706facing respective surfaces on the blade cores, and in the illustrated example, all of the respective surfaces are used to contact the adjacent blade core surfaces for providing the spacing defined by the thickness of the body portion. In another configuration, the surfaces can include respective bosses, bumps or dimples, for example, that would contact the adjacent blade core surfaces, and the spacing defined by the first body portion would be the spacing defined by the maximum thickness between the outermost surfaces of the bosses, bumps or dimples.

The spacer4700first body portion4702has a partially elliptical geometry, but may have other geometries. The first body portion extends in a direction parallel to a plane of the blade core in which the spacer is supported.

The first body portion4702of the spacer includes a flow diversion structure4708supported on a portion of the first body portion. The flow diversion structure in the present example is an extended structure with a surface that will extend in a space between adjacent blade cores, and in the present example, has the same thickness or spacing as the first body portion. In the illustrated configuration, the flow diversion structure4708is configured to extend in a general direction from an inner portion of a blade core to an outer portion of a blade core, and the structure may be curved to provide a curved flow surface for fluid, such as air or liquid.

The spacer4700also includes a second body portion4710extending adjacent the first body portion and along the axis of an away from the first body portion, and may, but need not, include an additional or secondary second body portion4712. In the illustrated configuration, the primary and additional or secondary second body portions are mirror images of each other relative to a plane perpendicular to the axis and through the first body portion, and have the same structure and function, but they can be configured differently. The second body portions form a blade engagement structure for limiting movement of the spacer, for example the first body portion, in a direction parallel to a plane of a blade core. The second body portions are configured to contact portions of respective blade cores between oppositely-facing surfaces of the respective blade core. In the present example, the second body portion4710extends into an opening, in the present example a partly elliptical opening4804(FIG.44) formed in the blade core4802. The second body portions and the opening can have other geometries, while still allowing the second body portion to be supported by the blade core in a direction parallel to a plane of the blade core. The profile are geometry of the second body portions and the profile or geometry of the opening in the blade core can be the same or substantially the same, but can also be different while the opening in the blade core can still support the second body portion and therefore the spacer at least partly in a plane of the blade core. Also, the second body portion can be solid, but in the illustrated configuration the second body portions include an opening4714(FIG.50) extending between the primary and secondary second body portions and through the first body portion.

The spacer can be formed from any one or more of the materials described herein, and can also be made from a material other than a working material. The spacer can be formed monolithic or out of multiple pieces. The spacer4700can alternatively be formed to have first and third body portions on opposite sides of a second body portion, analogous to the general structure of the spacer500(FIG.7). The spacer can be held in position in a respective opening in the blade core by any number of means, including those discussed herein, including interference fit, adhesive, welding, mechanical means or other means for reliably positioning the spacer in an opening in a blade core. The primary and secondary second body portions can have a thickness approximately equal to the thickness of a blade core, or may have a thickness approximately one half or less than one half the thickness of a blade core.

In the examples of the spacers4700described herein, one or more spacers can be supported on a blade core4800and/or adjacent blade cores484802. In the illustrated example, eight spacers are distributed equidistant from each other about each blade core, while other numbers of spacers and/or distributions are possible. In the illustrated example, all of the spacers on a given blade core are oriented generally the same as a function of the arcuate position on the blade core, for example so that a leading edge4716(FIG.47) is closer to the blade shaft opening402(FIG.46) and a trailing edge4718is closer to a perimeter404of the blade core, when the direction of rotation of the blade and spacer assembly is as indicated inFIG.46at4806. However, the orientation of one or more spacers can be altered or varied as desired. Generally, the arrangement and orientation of spacers on each blade core in an assembly will be consistent from one blade core to the next, for example so that stacking of blade cores into a blade assembly will produce the desired blade spacing and distribution of spacers about the blade assembly, for example if improved fluid flow is a consideration. In the illustrated example, the adjacent blade cores have the same number of spacers mounted on each blade core before the blade core and spacer assemblies are assembled onto a blade shaft, such as that described and illustrated inFIG.2. Adjacent blade cores will be pivoted 45° relative to each other as they are assembled into a blade core assembly.

Each blade core, for example4800and4802, includes one or more, and in the present example 8, airflow openings4808. As illustrated, the airflow openings4808are circular openings formed through each blade core, and in the present example positioned adjacent a leading portion of each flow structure. Additionally or alternatively, airflow openings can be positioned at other locations on a blade core. As adjacent blade cores are assembled on a blade shaft, airflow openings positioned at a given arcuate position on a blade core relative to a center of the blade shaft will be aligned with each other.

The blade cores4800and4802and spacers4700can be assembled to form a blade core and spacer assemblies, and a plurality of blade cores and spacer assemblies can be combined to form a blade assembly or blade head, such as may be used on a groover or a grinder in the present illustrations. The spacers are assembled onto a respective blade core in a manner similar to the assembly of the spacers4200on a blade core4250. The openings in the blade cores and the spacers supported in those openings in the blade cores generally coincide with an annulus defined by the fasteners in a pressure plate in a blade head in which the blade core and spacer assembly is assembled.

Another example of a spacer assembly includes a two-piece assembly5300(FIGS.52-54) having a first body portion5302and a second body portion5304. The first body portion extends outward from a central axis and has a maximum height or thickness in a direction parallel to the axis an amount that is selected to be equal to the desired spacing between adjacent blade cores5350and5352in a final assembly. The second body portion5304extends away from the first body portion along the axis, and in the present example the length of the second body portion along the axis is a combination of a length sufficient to extend into and through an opening in a blade core, so that the blade core can support the spacer in a direction parallel to a plane of the blade core, and an amount sufficient to receive a third body portion5306so that the third body portion can be secured on the second body portion to form the spacer assembly5300. The thickness of the third body portion5306will be the same as the thickness of the first body portion5302where the first and third body portions are used to determine the spacing between respective adjacent blade cores. Where the third body portion5306is used to determine the spacing between respective adjacent blade cores, the length of the second body portion will be such as to ensure that it does not extend beyond the outermost surface of the third body portion5306when the spacer is fully installed on a blade core. Alternatively, if the second body portion is used to determine the spacing between a blade core supporting the spacer5300and an adjacent blade core adjacent the third body portion5306, the thickness of the third body portion5306is selected so as to fully thread on the second body portion5304such that the second body portion extends beyond an outside and surface of the third body portion5306. Other configurations can be used for the spacer5300in a two-part form, and other means than threads can be used to secure the multiple components together to form the spacer assembly. For example, any of the spacers described herein can be formed as 2-part spacers or multiple-part spacers.

Each blade core5350and5352can be configured to support a 2-part spacer or multi-part spacer, for example the spacer5300or any of the other spacers described herein that could be formed as a 2-part spacer or multi-part spacer. In one example, the blade core5350includes an opening for receiving a respective spacer5300, and in the present example such opening is a circular opening in the blade core. In the illustrated configuration, four spacers5300are supported through respective openings in the blade core, distributed evenly about the blade core, and positioned so that they are coincident with an annulus defined by fasteners on a pressure plate. Other openings and circular and other distributions can be used as desired.

The blade core5350and the spacers5300can form an assembly of a blade core and spacers, and a plurality of blade core and spacer assemblies can be combined to form a blade assembly or blade head such as may be used on a groover or a grinder in the present illustrations. The illustrated blade core5350includes registration key slots216and217, each being part of a pair of diametrically opposite pairs of registration key slots. The blade core includes at least three and preferably four or more circular openings between the blade shaft opening402and the perimeter404. In an assembly of a blade core and spacers, the spacers are assembled on the blade core, and the blade core and spacer assembly mounted or positioned on a blade shaft. A next adjacent blade core and spacer assembly is then positioned on the blade shaft, pivoted 45°, or otherwise as selected. Multiple blade core and spacer assemblies are similarly positioned on a blade shaft to form a blade head, for example for use on machines described herein.

Any of the spacers described herein can be used to support one or more components that can have additional functions different than or in addition to a spacing function. In another example of a spacer having first and second body portions, a spacer5700(FIGS.55-58) includes first and second body portions5702and5704, respectively, which first and second body portions can have structures and/or functions analogous, similar or identical to the first and second body portions of spacers described herein. In the illustrated configuration, the first and second body portions have structures and functions identical to those described with respect to the first and second body portions4202and4212of the spacer4200(FIGS.40-43) except as described herein, and similar to the structures and functions of the first and second body portions514and520of the spacer500(FIGS.5-8). The first body portion5702extends outwardly parallel to a plane of a blade core, and along a central axis centered in the spacer. The first body portion has a maximum height or thickness in the direction of the central axis an amount that is selected to be equal to the desired spacing between adjacent blade cores5750and5752(FIG.55) in a final assembly. The first body portion can be any of a number of geometries, but in the illustrated configuration is substantially circular in profile.

The second body portion5704extends away from the first body portion along the central axis, and in the illustrated configuration is concentric with the first body portion, but can be otherwise. The second body portion is configured to contact a portion of the blade core5750between oppositely-facing surfaces of the blade core, and in the illustrated example, the second body portion passes through an opening in the blade core and contacts at least part of a wall forming the opening in the blade core. In the present example, the opening in the wall of the blade core would be a circular opening, but can be otherwise, preferably while still providing support for the spacer in a direction parallel to a plane of the blade core. As illustrated, the second body portion5704is a right circular cylinder, but it can take other geometric configurations that can also permit the second body portion to contact a wall of an opening in the blade core, for example so that the blade core can support the spacer, such as in a direction parallel to a plane of the blade core. Also in the present example, the second body portion is solid, but need not be, and could be hollow. The depth or thickness of the second body portion5704can be the same or less than a thickness of a blade core on which the spacer would be supported, and can be approximately equal to or less than one half the thickness of a blade core on which the spacer would be supported.

The spacer5700can be held in position in an opening in the blade core5750by any number of means, including interference fit, adhesive, welding, mechanical means or other means for reliably positioning the spacer in the opening in the blade core. An interference fit can be complete around the perimeter of a 360° contact, or may be partial with one or more points or one or more surfaces on the second body portion contacting respective surfaces in the opening in the blade core. The fit can be a close fit or no interference fit in an alternative configuration, and may be held in place by any of the other configurations described herein.

The illustrated spacer5700includes an engagement structure in the form of a groove5706. The groove supports an additional structure that may be a spacer structure or a structure with a different function, or one having a spacer and additional function. In the present example, the groove is an arcuate groove for supporting a guard ring5708(FIGS.55-56). The guard ring is an annular strip of material configured to fit in the groove5706of the spacer5700and similar grooves in spaced apart spacers5700on the blade core5750, so that the guard ring5708is adequately supported on the blade core through the associated spacers. The guard ring has a flat surface adjacent the facing surface of the blade core5750, and a flat surface on the oppositely-facing side of the guard ring. The thickness of the guard ring can be such as to allow the guard ring to provide a spacing function between adjacent blade cores. When the guard ring is assembled on the supporting spacers5700, the guard ring helps to resist intrusion of debris between the blade cores during operation. The guard ring can be held in place by any number of means, including interference fit or other mechanical securement, adhesive, welding, mechanical means or other means for reliably positioning the guard ring on the spacers. The guard ring may be formed from any number of materials, including steel, aluminum, thermoplastic and thermosetting materials or composite materials.

The blade core5750and the spacers5700can form an assembly of a blade core and spacers, and a plurality of blade core and spacer assemblies can be combined to form a blade assembly or blade head such as may be used on a groover or a grinder in the present illustrations, all of which may be accomplished in a manner identical or similar to the assembly of spacers and blade cores described herein with respect to other examples. In the assembly illustrated inFIG.55, a blade core and spacer and guard ring assembly can be assembled on a blade shaft, and a next adjacent blade core, spacer and guard ring assembly positioned on the blade shaft pivoted 45°. Additional blade core and spacer and guard ring assemblies can be positioned in a similar manner to produce a blade assembly or blade head for use on a machine.

In another example of a spacer, a spacer can have first and second body portions, where the first body portion provides a spacing function and a second body portion provides a support function for the spacer in a blade core, and additionally or alternatively, the first body portion can support a component for positioning the component on a blade core, and the spacer can be provided as a single monolithic part, or as two parts to be combined. As two parts, the first and second body portions can have structures and functions analogous to the first and second body portions in the spacer assembly5300(FIGS.52-54), and the spacer can have a third body portion analogous to the third body portion5306. In a further example of such spacers, a spacer5900(FIGS.59-68) can have a first component5902(FIGS.59-62) having a first body portion5904and a second body portion5906, having functions the same as first and second body portions in the other spacers described herein. In the illustrated configuration, the first body portion5904extends outwardly parallel to a plane of a blade core, and along a central axis extending through the spacer perpendicular to a plane of a blade core in which the first component5902is supported. The first body portion has a maximum height or thickness in the direction of the axis an amount that is selected to be equal to the desired spacing between adjacent blade cores, for example5908and5910(FIG.59) in a final assembly. The first body portion can be any of a number of geometries, but in the illustrated configuration has a deltoid.

The second body portion5906extends away from the first body portion along the axis, and in the illustrated configuration has a deltoid configuration with the geometry smaller than the deltoid configuration of the first body portion, but can be otherwise. The second body portion is configured to contact a portion of the blade core5908between oppositely-facing surfaces of the blade core, and in the illustrated example, the second body portion passes through an opening in the blade core and contacts at least part of a wall forming the opening in the blade core. In the present example, the opening in the wall of the blade core has a deltoid configuration, but can be otherwise, while preferably still providing support for the spacer in a direction parallel to a plane of the blade core. The second body portion5906can take other geometric configurations while also permitting the second body portion to contact a wall of an opening in the blade core, for example so that the blade core can support the spacer, such as in a direction parallel to a plane of the blade core. Also in the illustrated configuration, the first and second body portions are solid, but need not be, and could include hollow portions defined by one or more walls defining openings to produce the hollow portions. The depth or thickness of the second body portion5906can be the same or less than a thickness of a blade core on which the spacer would be supported, or could be greater than a thickness of the blade core, for example for providing a spacing structure on a side of the blade core opposite the first body portion5904, and/or for providing an engagement structure for an additional component, such as a third body portion.

The spacer5900can be held in position in an opening in the blade core5908by any number of means, including interference fit, adhesive, welding, mechanical means or other means for reliably positioning the spacer in the opening in the blade core. An interference fit can be complete around the perimeter of a 360° contact, or may be partial with one or more points or one or more surfaces on the second body portion contacting respective surfaces in the opening in the blade core. The fit can be a close fit or no interference fit in an alternative configuration, and may be held in place by any of the other configurations described herein.

In the illustrated configuration, the first spacer component5902includes an engagement structure in the form of one or more slots5912(FIGS.59and61). In the present example, the slots5912are a plurality of slots, extending away from a perimeter404of the blade core when the first component5902is positioned on a blade core. Each slot preferably has a non-radial geometry, for example to reduce the possibility of a component coming out of the slot under centripetal forces developed during rotation of the blade core. In the illustrated configuration, each slot is recessed into an outer face of the first body portion5904. The slot includes a straight walled portion5914and a rounded portion5916, where the rounded portion is at an internal end of the straight walled portion. The outer face of the first body portion also includes a recessed arcuate portion5918, which may have a radius of curvature similar to a portion of the blade core in which the first component5902is supported. The slots and the recessed arcuate portion in the present example are configured to receive one or more additional components to be supported on the blade core, for example in an area of a perimeter portion of the blade core. In the illustrated configuration, each first component5902supports a pair of oppositely-extending guard components5920(FIGS.59and69). The guard components are similar in function to the guard ring5708(FIGS.55-56), and the guard components combined into an assembly form a guard ring in the area of the perimeter of each blade guard. Alternatively or additionally, the guard components can provide spacing functions in the assembly. In the present example, the guard components are held in place by mechanical engagement, but they can be held in place by any number of means, including interference fit or other mechanical securements, adhesive, welding, mechanical means or other means for reliably positioning the guard components on the spacers. The guard ring may be formed from any number of materials, including steel, aluminum, thermoplastic and thermosetting materials or composite materials.

The spacer assembly5900includes a second component5930(FIGS.64-68) that can be combined with the first component5902to form the spacer assembly5900. In the illustrated configuration, the second component forms a third body portion5932, which can serve as a spacer structure either completely for a side of the blade core5908opposite the first body portion5904, or in combination with a portion of the second body portion5906that extends beyond the opening in the blade core, for example as illustrated inFIG.69. The third body portion5932is supported on the second body portion5906, which in turn is supported in a plane of the body core by the opening in the body core. The first and second components5902and5930can be secured together by any one or more of a number of means, including interference fit, adhesive, welding, mechanical means or other means for reliably securing the two parts together.

The third body portion can take a number of geometries, but in the illustrated example has a deltoid with a deltoid opening5934for receiving the second body portion5906. The third body portion includes a thickness5936(FIGS.67-68), in the present example selected to be equal to the desired spacing between adjacent blade cores, but can be otherwise, for example where the second body portion5906is relied upon for providing all of the spacing function for the side of the spacers5900opposite the first body portion5904.

The second component5930includes an arcuate recess5936for receiving a guard component supported on a spacer on an adjacent blade core, for example as illustrated inFIG.69. As shown inFIG.69, the recess5936in the second component5930on the blade core5908supports a guard component5920against a surface of the recess5936. The guard component5920supported in such a way is supported through interlocking engagement with one or more spacer assemblies5900positioned on the adjacent blade core5910.

Each blade core, for example blade cores5908and5910, can support one or more of the spacers5900. In the illustrated configuration, each blade core supports four spacers and four ring guards, as well as four additional ring guards from and immediately adjacent blade core, supported on the arcuate recess is5936on the second components5930. Other numbers and configurations of spacers5900or other spacers can be included on each blade core.

A blade core and spacer assembly is formed by inserting a first component5902in an opening5950in the blade core5908so that the second body portion5906extends into and through the opening. The openings can be formed in the blade core5908in an annular area coincident with an annulus formed by an assembly of fasteners arranged on a pressure plate such as illustrated inFIG.2, or in the illustrated example, the openings can be placed closer to the perimeter404of the blade core, for example to position the guard components5920closer to the gullets408in the blade cores. The second component5930is then placed over the second body portion so that the blade core5908is sandwiched between the first and third body portions. The other spacers5900are assembled onto the blade core5908through respective openings in a similar manner. First and second guard components5920are then inserted in respective slots5912in the first component5902, and the opposite ends of the guard components and additional guard components are placed in respective slots5912on respective spacers on the blade core5908.

A plurality of blade core and spacer assemblies can be positioned on a blade shaft to form a blade assembly or blade head, such as may be used on a groover or grinder in the present illustrations. The blade core and spacer assembly can be positioned on a blade shaft so that the registration key slots206align with a registration key on the blade shaft. A second blade core5910and spacer assembly can be positioned on the driveshaft, with the blade core shifted 45°. The first and third body portions along with part of the second body portion of each spacer provides spacing between each adjacent blade core, and the recesses5936on the second component5930of each spacer on a given blade core helps to support the guard components5920on an adjacent blade core.

An example of blade and spacer assemblies assembled into a blade head is illustrated inFIG.70(not showing the blade shaft and mounting hardware and working elements), and illustrates an assembly that can be composed of any of the blade core and spacer assemblies described herein, which would be placed on a blade shaft one or several at a time as described herein. Additionally, any of the blade core and spacer assemblies described herein can be assembled into a blade head and mounted on a blade shaft with adapter plates at each end of the complete assembly of blades to serve as an interface between the end-most blades and spacers and end plates or pressure plates used to secure the blades in the blade head, for example as illustrated inFIGS.2and3. The blade assembly7000(FIG.70) includes a plurality of blades7002assembled and arranged as described herein. The blades can be mounted on a blade shaft such as that described with respect toFIG.2, or a blade shaft such as that described with respect toFIG.3. The blade assembly includes an adapter plate7004at a first end of the blade assembly and a like adapter plate (not shown) at the opposite end of the blade assembly. Only one adapter plate will be described. In the illustrated configuration, the adapter plate is a disc, made from metal or other suitable material that can withstand the expected compressive loads. The adapter plate is a substantially flat annular disc having an opening7006for the blade shaft from which registration key slots7008and7010extend radially outward. One or the other pair of the registration key slots will align with a registration key or keys on the blade shaft. For blade assemblies to be used on grinding and grooving machines, the opening7006for the blade shaft has an inside diameter ranging between 3 inches up to 10 or 12 inches or more. The adapter plate extends radially outward to an outer perimeter7012, in the present example approximately at the gullets of the blades.

The adapter plate includes openings for accommodating spacers and any other structures projecting outward from the end-most blade core. Alternatively, the end-most blade core can be assembled with half spacers, which do not project beyond the outermost surface of the end-most blade, in which case a pressure plate or endplate can bear up against the respective end-most blade core and any clamping pressure would be uniformly distributed over the blade core.

The adapter plate7004includes a cavity7014for receiving each of a respective spacer (described more fully below) on an end-most blade core. In the illustrated example, the cavity7014is an opening extending completely through the adapter plate from one side surface through to the other side surface, and the thickness of the adapter plate is selected so that any spacer or other projection on the end-most blade core is at least flush with or recess below the outer side surface of the adapter plate7004. Each cavity7014can be circular or other geometry suitable for receiving the spacer or projection, and in the illustrated example, the cavity geometry is the same as the geometry of the spacer extending into the cavity. Generally, the adapter plate7004will have the same number of cavities or openings as there are spacers and/or projections on the blade core. In another configuration, the geometry of the cavity can be a uniform or generic geometry, such as a circle or a rectangle, to accommodate a variety of spacer geometries, for example when one blade assembly is changed out for a different blade assembly having different spacers.

In another example of a spacer that can be used with blade cores and supported by a blade core and/or by a rod or shaft, a spacer7400(FIGS.70-77) is configured to be supported by a blade core, and in one configuration contact a portion of the blade core intermediate oppositely-facing sides of the blade core, for example a wall of an opening formed in the blade core. The spacer7400includes a first body portion7402to serve as a spacer element between a blade core on which the spacer7400is supported and a next adjacent blade core. The first body portion is that portion of the spacer that extends along and outward along an axis7403from an adjacent surface of a blade core. The first body portion extends in a first direction from a plane including a first surface7404to a second surface7406. The distance in the first direction, for example from the first side7404to the second side7406of the first body portion can be used to define the spacing between adjacent blade cores, for example a first blade core7480and a second blade core7482(FIGS.71-72). In the present configuration, the thickness defines the maximum spacing between adjacent blade cores. The first body portion is mounted on or supported by the first blade core, and the axial distance or thickness of the first body portion is used as a spacer between the first blade core7480and the second blade core7482, and likewise with other blade cores on which the spacer7400is used. The first body portion includes respective surfaces on the first and second sides7404and7406, respectively, and the surface on the side7404faces the oppositely-facing surface on the blade core on which the spacer is supported, and the surface on the side7406faces the oppositely-facing surface on the next adjacent blade core. In one configuration (not illustrated), the second side7406can be completely flat over the entire extent of the first body portion for contacting the surface of the adjacent blade core. Alternatively (also not illustrated), the second side7406can be other than flat so that the outer-most surfaces on the second side would be used to define the thickness of the first body portion and therefore the spacing between adjacent blade cores.

The first body portion7402of the spacer7400extends outwardly to a perimeter surface7408, which can take a number of configurations, but in the illustrated example includes an inner circular portion7410and an outer arm, branch or lobed portion7412. As described more fully below, the outer lobed portion will be positioned radially outward of the circular portion4710when positioned on a blade core, and the outer lobed portion provides an extended structure for providing the spacing function and for compressive loading.

The spacer7400also includes a second body portion7414extending adjacent the first body portion and extending along the axis7403. The second body portion forms a blade engagement structure for limiting movement of the spacer, for example the first body portion, in a direction parallel to the plane of the blade core. The second body portion is configured to contact a portion of the blade core7480or7482between oppositely-facing surfaces of the blade core. In the present example, the second body portion extends into an opening, in the illustrated example an opening7484having a suitable for receiving laterally a spacer7400into the opening and then allowing the spacer to move parallel to a blade core to a final position. The geometry of the opening can take a number of configurations, which may be selected at least in part as a function of the configuration of a spacer. The geometry of the spacer and of the opening or selected so that the blade core can reliably support the spacer during normal operation. The second body portion includes a semicircular portion7416and a straight walled portion7418. The semicircular portion allows the second body portion to be reliably seated in an opening, and the straight walled portions can be used to limit pivoting of the spacer7400, as a function of the geometry of the opening7484into which the spacer is positioned. The second body portion has a thickness approximately the same as a thickness of the blade core7480/7482, taking into account tolerances and the like, and may have a thickness that accommodates easy positioning of the spacer in the opening7484in the blade core while still allowing the first body portion7402to maintain the desired spacing between the blade core7480and an adjacent blade core7482which the sides7406will contact when the blade cores are assembled to be adjacent each other.

In a configuration of the spacer7400having only a first body portion7402and a second body portion7414(not illustrated), or in the illustrated configuration, the spacer can be supported in a blade core, for example blade cores such as7480/7482, by any number of means. For example, the spacer can be supported in the blade core in an opening with an interference fit or a close fit, by mechanical means including for example by rods if used (such as with an assembly with a blade shaft302described with respect toFIG.3), welding, adhesive or other means for reliably holding the spacer in position. In the illustrated configuration, the spacer is supported on a blade core partly by a third body portion.

The spacer7400includes a third body portion7420extending along the axis7403away from the second body portion and away from the first body portion. The third body portion includes a wall that can help to position the spacer7400on the blade core, and also include a structure to serve as a spacer element between the blade core on which the spacer is supported and a next adjacent blade core (different from the next adjacent blade core closest to the first body portion). In the illustrated configuration, the first and third body portions are mirror images of each other about a plane bisecting the second body portion parallel to the blade core on which the spacer is supported and perpendicular to the axis7403. The third body portion includes first and second sides7422and7424, respectively (FIG.74-75), and the surface on the side7422faces the oppositely-facing surface on the blade core in which the spacer is supported, and the surface on the side7424faces the oppositely-facing surface on the next adjacent blade core. In one configuration (not illustrated) the second side7424can be completely flat over the entire extent of the third body portion for contacting the surface of the adjacent blade core. Alternatively (also not shown), the second side7424can be other than flat so that the outer-most surfaces on the second side would be used to define the thickness of the third body portion and therefore the spacing between adjacent blade cores.

The first sides of the first and third body portions, and the perimeter surface of the second body portion form a channel7426(FIG.74) extending about a majority of the perimeter of the second body portion. The channel is configured to receive the exposed wall of an opening in the blade core so that the spacer can be positioned in the opening and supported by the blade core, which support may be by either or all of contact with the channel bottom formed by the surface of the second body portion, or being sandwiched between the first walls7404and7422of the first and third body portions. Portions of the first and third body portions sandwich a portion of the blade core to help position the spacer laterally relative to the blade core. The spacing of the first walls of the first and third body portions can provide an interference fit, in which case the spacer can be reliably supported on the blade core during normal operation, especially with the centripetal forces developed during rotation of the blade core, for example if the second walls7406and7424of the first and third body portions are completely flat. The spacing of the first walls can also provide a close fit, making it easier to position the spacer in the opening, and the closeness of the fit will help to determine how easy it is to position the spacer and how easy it is to shift the spacer before a final assembly is complete. The spacing can also provide a clearance fit, in which case the spacer may be held in place by other means, such as a template, fixing structure or other temporary positioning device until assembly is complete, or more permanent means such as welding, adhesive, or the like. The form of the fit may apply equally over the entire length of the channel7426, or the channel may have one fit configuration at one or several locations and other fit configurations at other locations of the channel, thereby providing some flexibility over the form of the fit between the spacer in the blade core.

In the illustrated example, the first and third body portions include converging walls7428and7430(FIGS.75-76), respectively, at an approximate middle portion of the channel7426to assist in aligning the spacer with the blade core wall in the opening in which the spacer is to be positioned. The converging walls can extend along the walls of the groove or channel as far as desired.

The spacer7400(and therefore the first, second and third body portions) include a wall7432concentric with the axis7403extending through the spacer. The opening provides for lighter parts and may be used to accommodate blade shaft rods such as positioning rods308described with respect toFIG.3when the spacers7400are used on blade cores that would be assembled into a blade head on a blade shaft such as302. The spacers can also be used with blade cores that would be assembled onto a blade head on a blade shaft such as that described with respect toFIG.2, and indexing rods (not shown) or other structures can extend through the openings7432to help support the spacers and maintain their radial position. Alternatively, if the spacers7400are to be supported with positioning rods308or indexing rods or similar structures, the spacers7400can be configured to omit the second body portions7414,7434and7436, and include the first body portion7402and the third body portion7420as separate spacers on opposite sides of a blade core supported by rods308or indexing rods, as desired. In such a configuration, the first and third body portions would typically be identical spacers positioned on a rod or other structure to maintain the desired radial spacing from the main shaft. The inner circular portion for each body portion would form a ring segment, in the present example a complete circular ring segment, for extending around the rod or other structure. The outer lobed portions7412form branches that branch out from the opening7432to provide additional support for spacing and withstand compression from the pressure plates. Each outer lobed portion in the illustrated example is an integrated structure, but the structure can be formed as multiple discrete structures, branches extending outwardly, or the like. The outer perimeter of each lobed portion extends approximately arcuately. Other configurations for the outer lobed portions are possible.

The spacer7400may also include, as illustrated, additional or auxiliary second body portions7434and7436on either or both of the first and third body portions7402and7420, respectively. The additional, secondary or auxiliary second body portions7434and7436have structures and functions identical to the additional, secondary or auxiliary second body portions4312and4314described with respect toFIG.43A, and they engage corresponding openings in adjacent laid cores substantially as described with respect to the spacer4300. The additional or secondary second body portions7534and7536are formed as bosses or projections extending outwardly from the respective body portions, and form a shoulder or perimeter wall extending in a circle. Alternatively, the secondary second body portion may be formed in segments, bumps, dimples, tabs or other structures forming an equivalent or analogous structure to a shoulder or perimeter wall, for example intermittent or segmented. The secondary second body portion is configured to engage an opening in an adjacent blade core having a geometry substantially matching that of the secondary second body portion. Engagement in such an opening in an adjacent blade core can be by interference fit, close fit or clearance fit, providing a desired amount of support between the two structures.

The outermost surface of each secondary second body portion includes a substantially flat surface, and the height of the secondary second body portion from the adjacent first/third body portion can be equal to or less than a thickness of the blade core into which the secondary second body portion extends. In the illustrated configuration, the height of the secondary second body portion is approximately one half or less than one half the thickness of the adjacent blade core, so that respective secondary second body portions on opposite sides of the adjacent blade core can extend into the opening with the desired contact between the secondary second body portions or without any contact, as desired.

The spacer7400can also include a flow device7700(FIG.77), if desired. The flow device can take a number of configurations, but in the illustrated configuration includes a support structure7702for mounting on the spacer7400. The flow device can be mounted in other configurations, for example on other spacers having different configurations, in which case the support structure may have a different geometry. In the illustrated configuration, the support structure includes an opening7704complementary to the outer profile of the spacer7400. The thickness of the support structure, and the spacer overall, may be approximately equal to the thickness of a first or third body portion on which the flow device may be supported, namely approximately the thickness of a spacing between adjacent blade cores, or can be less than the thickness. The flow device also includes a flow structure7706having a structure and function substantially the same as the flow structure4708described with respect toFIGS.44-51. The positioning of the flow device will also be similar to that described with respect to the flow structure4708.

Each spacer7400is substantially solid except for the channel7426and the through opening7432, and the first, second, third and secondary second body portions are formed monolithic and otherwise solid, but can be otherwise. Each spacer7400can be formed from multiple parts, or each spacer7400and a flow device such as flow device7700can be formed monolithic.

Another example of a blade core for a grinding or grooving machine having one or more openings illustrated inFIGS.71-73includes a blade shaft opening402and a perimeter404with registration key slots216and217. The blade core has an arbor opening of at least 3 inches up to about 12 inches or more for being supported on the blade shaft for grinding or grooving. The blade core includes a noncircular opening, and in the present example a plurality of noncircular openings7484for receiving and supporting respective spacers7400. In the example illustrated, there are six identical noncircular openings7484, and only one will be described. The noncircular openings7484include a first somewhat elliptical portion7486closer to the perimeter404than the remainder of the opening7484. The elliptical portion joins a intermediate converging wall portion7488in an intermediate portion of the opening7484, which in turn converges to an end portion7490having straight walls7492ending at a semicircular wall7494. As illustrated, the geometry of the opening7484allows the spacer to fit into the elliptical and intermediate portions laterally or sideways relative to the blade, and then allow the spacer to be moved radially inward so that the second body portion can contact and engage the straight walls and the semicircular wall of the opening. The size of the spacer relative to the size of the opening allows either the first or third body portions to enter and pass through the opening7484from one side of the blade core to the other side. The geometric profiles can be different while the size of the spacer can be selected so as to permit the desired movement of the spacer in a respective opening in the blade core.

The openings7484are distributed uniformly about the blade core, and the portion7490of the opening can be selected so as to be positioned approximately on the annulus defined by the fasteners applying pressure to the pressure plate. More or fewer than six openings can be used as desired. In the illustrated configuration, the blade core also includes circular openings7496(FIGS.71-73). The openings7496can be distributed substantially uniformly about uniformly about the blade core, or otherwise, but in the illustrated configuration, the openings7496are configured to receive one or both of secondary second body portions on spacers supported by adjacent blade cores. In another configuration (not shown), the openings and the secondary second body portions that extend into such openings may have a different configuration than circular, including for example a profile more similar to the profile of the first and third body portions on the spacer7400.

In a further example of a blade core and spacer assembly, blade cores7480and7482can include the desired number of spacers7400, and multiple such blade core and spacer assemblies can be combined adjacent each other to form a blade head on a blade shaft, such as either of those described with respect toFIG.2-3. Adjacent blade cores are assembled with a first blade core pivoted 30° relative and immediately adjacent blade core so that the secondary second body portions on the immediately adjacent blade core can extend into the circular openings7496of the subject blade core. When the desired number of blade core and spacer assemblies are positioned on the blade shaft, and the secondary second body portions of each spacer extend into respective circular openings in the immediately adjacent blade cores on each side, the assembly as well supported arcuately and axially, and positioning of the adapter plates7004sandwich the blade core and spacer assemblies together. Application of a pressure plate applies a compressive load to the assembly, substantially locking all of the components together in a blade head.

The assembly can also include flow devices such as flow devices7700positioned on all or fewer than all of the spacers7400. The flow surfaces would generally be directed in the same way relative to a radius of the blade core, but they can be directed otherwise to produce the desired flow configuration. Fluid flow, for example air or liquid flow, can be directed at least partly radially outward, and flow may also be assisted by the outer portions7486of the openings7484.

In a further example of a spacer that can be used with blade cores, including on a blade head, a spacer7800(FIGS.78-79) is configured to be supported radially by a rod or other structure, for example a rod308in a blade head300or other structure in a blade head. The rod or other structure will support the spacer at a desired radial distance from the main blade shaft302. The spacer is configured to contact a portion of a blade core face on one side7802and contact a portion of another blade core face on a second side7804, and the thickness of the spacer7800is chosen to define the desired spacing between adjacent blade cores, for example a first and second blade core. In the present example, the thickness of the spacer7800is substantially the same over the entire spacer structure.

In the illustrated example, the spacer7800is a monolithic structure having substructures wherein each substructure includes multiple components, and all of the substructures are formed together as a monolithic structure extending generally in a circle. In the present example, the substructures are substantially identical, but they can be different from each other or different from at least one other substructure, according to the desired configuration. The spacer7800can be formed in a number of ways, including cut from a plate or other solid material, or formed and assembled from individual substructures. In the present example, the spacer7800is an extruded structure and cut and finished to the desired thickness for the desired spacing between adjacent blade cores. The spacer can be formed from any of a number of materials, and in the present example extruded aluminum, but may also be formed from engineered plastics, including thermosets and thermoplastic materials. The spacer web elements are substantially solid and formed by the web elements described herein.

As with a number of the foregoing spacers, including several of the configurations of the spacers4300and7400described herein, the spacers can be connected with webbing or other structures to form the spacers into a connected structure, for example at least two adjacent spacers or more spacers can be connected to each other so that they can be used to be positioned between a pair of spaced apart blade cores. In the illustrated example of spacer7800, the spacer is formed from a plurality of substructures7806, and in the present example the substructures are all identical and repeated next to each other forming a circular spacer7800, but the substructures can be other than identical. As an extrusion, the substructures can be easily identical or different. In the following description, only one substructure7806will be described, for the present spacer7800, which has eight substructures, but reference numbers may be included in web elements of other substructures illustrated for purposes of clarity in the illustration. The number of substructures in the spacer can be selected as desired. Eight substructures can accommodate a blade head having 4 rods and a blade head having 8 rods. In the present example where the substructures are substantially identical, the transition from one substructure to an adjacent substructure can be selected as desired, but in the present description, the substructure will be centered on the structure being supported by a rod or other support structure as defined by imaginary radial cuts7808and7810centered on a center7812, coincident with a central axis of a main blade shaft of the blade head.

In the spacer7800, the substructure7806(and each of the other substructures in the illustrated configuration) includes a first body portion7814to serve as a spacer element between adjacent blade cores. The first body portion extends in the direction of the axis at the center7812to define a thickness between oppositely facing surfaces7802and7804, each of which define respective planes containing the oppositely-facing surfaces. The thickness defines the maximum spacing between adjacent blade cores.

The spacer7800includes at least one ring segment7816. In the present example, the ring segment forms a complete circle having an inner circumference defining an inner surface7818, but in other configurations the ring segment can form a semi circle or a partial circle. The inner surface7818can be smooth and substantially conform to an outer surface of a rod308with a diameter greater than or equal to an outer diameter of the rod, but alternatively the inner surface can be other than smooth so that inward projecting surfaces can contact an outer surface of the rod while intermediate surfaces between the inward projecting surfaces are spaced apart from the rod surface. The ring segment is configured to be supported at least in part by a rod308in the blade head assembly. The ring segment includes an outer surface7820that in the present example is also substantially circular except for the outwardly extending web components described herein, but the outer surface may be other than circular. If the ring segment is only a partial circle, one or more openings in the ring segment can be formed anywhere around the perimeter of the ring segment, but an opening is preferably made on the portion of the ring segment facing at least partly inward toward the center7812to minimize exposure to the opening of dust and debris.

The spacer7800includes at least one and in the present example a plurality of lobes or branches extending away from the ring segment. One or more lobes or branches can extend inwardly toward the center7812or outwardly away from the center. In the present example, the spacer includes a first branch7822extending radially inward from a center of the ring segment, and a second branch7824extending radially outward from a center of the ring segment. In one configuration, the first and second branches extend approximately at least an annular distance to coincide with an envelope formed by and between the first and second pressure plates310and312. In the illustrated example, the first branch7822extends inwardly while leaving a gap so as to be spaced apart from the outer surface of any main blade shaft on which the blades are to be mounted and supported. The first and second branches and any structures attached to them provide extended structures for providing the spacing function and for receiving compressive loading.

The first branch in the present configuration includes at least one arm and in the present example two arms7826and7828extending away from the first branch. In the present example, the first and second arms extend away from an end of the first branch, but the first branch can extend further radially inward if desired, and may include one or more additional arms or other structures. In the illustrated configuration, the first and second arms extend arcuately in opposite directions from the first arm7822. They have a curvature similar to or the same as a curvature of the ring segment7816, and a radius of curvature less than a radius of curvature of a blade with which the spacer is to be used, but they may be curved otherwise or may be straight. The first and second arms may be configured to be within an envelope of the first and second pressure plates310and312.

The second branch in the present configuration includes at least one arm and in the present example first and second arms7830and7832extending away from the second branch. In the present example, the first and second arms extend away from an end of the second branch, but the second branch can extend further radially outward if desired, and may include one or more additional arms or other structures. In the illustrated configuration, the first and second arms7830and7832extend arcuately in opposite directions from the second arm, and they have a curvature forming an arc of a circle defined by a radius from the center7812to the first and second arms7830and7832. They may take another curvature or may be straight or follow another profile as desired. The first and second arms7830and7832may be configured to be within an envelope of the first and second pressure plates310and312. In the present example, the first and second arms7830and7832extend over an arc defined by almost ⅛ of a circle containing the first and second arms centered on the center7812, but they may extend more or less than the relative distance illustrated.

The spacer7800includes in the present example additional lobes or branches extending away from the ring segment7816, for example a third branch7834extending laterally of the ring segment, and also in the present example a fourth branch7836extending laterally of the ring segment in a direction opposite the third branch. The third and fourth branches extend arcuately from the ring segment and not only provide spacing and compression functions, but also are used to connect respective adjacent spacers or substructures. The third and fourth branches have radii of curvature to extend arcuately along a circle centered on the center7812on a radius at which the third and fourth branches are positioned, and corresponding approximately to a radius between the center7812and a center7838of the ring segment7816. The third and fourth branches extend to and connect with respective fourth and third branches in respective adjacent spacers or substructures. If a ring segment is less than a complete circle, any opening formed in the ring segment is preferably interior to the third and fourth branches3834and3836, to minimize injury inside the ring segment of dust, moisture or debris.

Each of the third and fourth branches includes respective radial arms7840and7842, respectively, in the present example extending on respective radii from the center7812. Each radial arm includes a portion extending radially outward from its branch and a portion extending radially inward from its branch.

A given spacer can be defined by a single substructure such as substructure7806, but in the example illustrated, the spacer78includes a plurality of substructures, each connected to respective ones of a pair of adjacent substructures. The spacer in the example illustrated may include anywhere from one, two, three, etc., up to eight substructures, in any desired combination. For example, a spacer assembly can be formed from four pairs of two substructures, two pairs of four substructures, or two pairs of three substructures and one pair of two substructures, etc. Separate substructures can be made separately and attached together, may be overlapping, or may have a gap between separate but adjacent substructures.

With spacers7800, a cutting head may be assembled with a main shaft, for example the main shaft302(FIG.3) and a plurality of blades304supported on the main shaft and positioned using the rods308extending parallel to the main shaft. The rods extend into respective openings in the blades, and spacer elements7800are positioned between adjacent blades so that the rods extend through the openings of respective ring segments7816. Where the cutting head includes 4 rods, the rods will extend through the openings in alternating ring segments in the spacer7800, and where the cutting head includes 8 rods, a rod will extend through each of a respective ring segment. In one configuration, the spacer will include lobes, branches and/or arms extending away from a respective ring segment while still falling at least partly within an envelope defined by the pressure plates310and312, specifically within an annulus defined by the outside diameter of the main shaft and the outside diameter of pressure plates310and312.

Having thus described several exemplary implementations, it will be apparent that various alterations and modifications can be made without departing from the concepts discussed herein. Such alterations and modifications, though not expressly described above, are nonetheless intended and implied to be within the spirit and scope of the inventions. Accordingly, the foregoing description is intended to be illustrative only.