U.S. patent application number 10/038328 was filed with the patent office on 2003-07-03 for reciprocating saw.
Invention is credited to Harman, William G. JR., Kelican, Earl, Turner, Terry L., Wheeler, Thomas J..
Application Number | 20030121389 10/038328 |
Document ID | / |
Family ID | 21899317 |
Filed Date | 2003-07-03 |
United States Patent
Application |
20030121389 |
Kind Code |
A1 |
Wheeler, Thomas J. ; et
al. |
July 3, 2003 |
Reciprocating saw
Abstract
A reciprocating saw includes a carrier operable to cooperate
with a motor to translate rotational movement of the motor into
reciprocal linear actuation of a saw blade. A carrier is slidably
disposed within the housing and includes a first portion adapted to
receive a saw blade and a second portion having a slot
therethrough. A rotatable element is fixed for rotation about an
output shaft of the motor. A follower operably interconnects the
carrier and the rotatable element wherein rotation of the rotatable
element provides reciprocal linear motion of the carrier whereby
the follower follows a reciprocal linear path within the slot.
Inventors: |
Wheeler, Thomas J.; (Pomona,
CA) ; Turner, Terry L.; (Westminster, MD) ;
Harman, William G. JR.; (Glen Rock, PA) ; Kelican,
Earl; (New Oxford, PA) |
Correspondence
Address: |
HARNESS, DICKEY & PIERCE, P.L.C.
P.O. BOX 828
BLOOMFIELD HILLS
MI
48303
US
|
Family ID: |
21899317 |
Appl. No.: |
10/038328 |
Filed: |
January 2, 2002 |
Current U.S.
Class: |
83/699.21 ;
30/392 |
Current CPC
Class: |
B23D 51/02 20130101;
Y10T 83/9481 20150401; B23D 51/16 20130101; Y10T 83/04 20150401;
B23D 51/10 20130101; B23D 49/162 20130101 |
Class at
Publication: |
83/699.21 ;
30/392 |
International
Class: |
B27B 019/00 |
Claims
What is claimed is:
1. A reciprocating saw comprising: a housing containing a motor; a
carrier slidably disposed within said housing, said carrier
including a first portion having a channel adapted to receive a saw
blade and a second portion having a slot therethrough; a rotatable
element fixed for rotation about an output shaft of said motor; and
a follower for operably interconnecting said carrier and said
rotatable element wherein rotation of said rotatable element
provides reciprocal linear motion of said carrier whereby said
follower follows a reciprocal linear path within said slot.
2. The reciprocating saw of claim 1, wherein said slot includes
lateral walls extending from opposing edges thereof.
3. The reciprocating saw of claim 2, wherein said lateral walls
include a first and second pair of laterally opposed walls, said
first pair of walls laterally offset from said second pair of walls
by a first and second channel formed in said carrier member.
4. The reciprocating saw of claim 3, wherein said channels are
oriented whereby said output shaft extends therethrough as said
follower follows said reciprocal linear path within said slot.
5. The reciprocating saw of claim 4, wherein said follower includes
a slider laterally extending in a first direction a width so as to
slidably interfit between said first and second laterally opposed
walls and in a second direction a width greater than said
channels.
6. The reciprocating saw of claim 5, wherein said follower further
includes a roller coupled to said slider, said roller configured to
rotatably interface said lateral walls as said follower follows
said reciprocal linear path within said slot.
7. The reciprocating saw of claim 6, wherein said housing further
includes a fan operable to direct air through said second portion
of said carrier to said first portion of said carrier.
8. The reciprocating saw of claim 7, whereby said fan further
directs air out of said housing through vents incorporated
therein.
9. The reciprocating saw of claim 1, wherein said reciprocating saw
further includes a releasably attached base portion, said base
portion including a first pair of lateral rails extending therefrom
for slidably engaging a second pair of lateral walls incorporated
on said housing.
10. The reciprocating saw of claim 10, wherein one of said housing
and said base further includes a latch for selectively coupling
said base to said housing.
11. A reciprocating saw comprising: a housing containing a motor; a
saw blade having a cutting edge, a mounting edge and a side
surface, said side surface defining a first plane; a carrier member
having a first portion including a base defining a second plane,
said base adapted to receive said saw blade wherein said first
plane is parallel to said second plane, and a second portion in
communication with said motor, said second portion having a slot
therethrough defining a guide path; a rotatable element fixed for
rotation about an output shaft extending from said motor; a
follower for operably interconnecting said carrier and said
rotatable element wherein rotation of said rotatable element
provides reciprocal linear motion of said carrier whereby said
follower follows a reciprocal linear pattern within said guide
path.
12. The reciprocating saw of claim 11, wherein said lateral wall
sections include a first and second pair of laterally opposed
walls, said first pair of walls laterally offset from said second
pair of walls by a first and second channel formed in said carrier
member.
13. The reciprocating saw of claim 12, wherein said channels are
oriented whereby said output shaft extends therethrough as said
follower follows said reciprocal linear path within said slot.
14. The reciprocating saw of claim 11, wherein said follower
includes a slider rotatably coupled thereto, said slider laterally
extending in a first direction defining a width so as to slidably
interfit between said first and second laterally opposed walls and
in a second direction a width greater than said channels.
15. The reciprocating saw of claim 14, wherein said follower
further includes a roller coupled to said slider, said roller
configured to rotatably interface said lateral walls as said
follower follows said reciprocal linear pattern within said guide
path.
16. The reciprocating saw of claim 11, wherein said housing further
includes a fan operable to direct air through said second portion
of said carrier to said first portion of said carrier.
17. The reciprocating saw of claim 16, whereby said fan further
directs air out of said housing through vents incorporated
therein.
18. The reciprocating saw of claim 11, wherein said reciprocating
saw further includes a removable base, said removable base
including a first pair of lateral rails extending therefrom for
slidably engaging a second pair of lateral walls incorporated on
said housing.
19. The reciprocating saw of claim 18, wherein one of said housing
and said removable base further includes a latch for selectively
coupling said removable base to said housing.
20. A reciprocating saw comprising: a housing containing a motor; a
saw blade having a shank portion and a cutting portion; a carrier
having a first portion adapted to receive said saw blade and a
second portion in communication with said motor, said first portion
including a pair of lateral walls and a base portion extending
therebetween; a clamp extending from said lateral walls and
operable to engage said saw blade at an interface edge to retain
said shank portion of said saw blade within said first portion of
said carrier; and a cam member extending between said lateral
walls, said cam member positioned from said base portion forming a
channel to receive said saw blade, said cam member extends adjacent
a portion of the blade between said interface edge and said cutting
portion.
21. A reciprocating saw comprising: a housing containing a motor; a
drive mechanism coupled to said motor; a carrier disposed within
said housing and operable to interconnect a saw blade to said drive
mechanism for translating rotational movement of said motor into
linear actuation of said saw blade; and a releasably attached base
portion, said base portion including a first pair of lateral rails
extending therefrom for slidably engaging a second pair of lateral
rails incorporated on said housing, one of said housing and said
base further including a latch for selectively coupling said base
to said housing.
22. The reciprocating saw of claim 21, wherein said latch is biased
into an engaged position against a stop extending from said
base.
23. The reciprocating saw of claim 22, wherein said latch is
movable between said engaged position and a disengaged position.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to reciprocating saws and more
particularly to a reciprocating saw arrangement operable to
translate rotational movement of a power source into reciprocal
linear actuation of a saw blade.
BACKGROUND OF THE INVENTION
[0002] Craftsman and builders have used reciprocating saws and
jigsaws throughout the industry to perform various cutting
operations. A conventional reciprocating saw or jigsaw generally
consists of a housing having a motor, a drive mechanism for
translating rotational motion of the motor into linear actuation of
a carrier or drive shaft, and a saw blade releasably coupled to the
drive shaft. Such conventional arrangements however present a few
drawbacks which decrease usability and longevity of the tool. For
example, during a cutting operation, woodchips or debris from the
workpiece tend to collect around the clamping mechanism holding the
saw to the tool. Furthermore, in some instances debris can be
ingested into the drive mechanism of the saw. It would be desirable
to provide a saw that created a positive pressure at the blade,
clamping mechanism interface to inhibit debris from collecting in
the area or travelling into the drive mechanism.
[0003] In addition, conventional reciprocating saws generally
include a handle extending at a 180 degree angle while jigsaws have
a handle extending at 90 degrees. It would be an advantage to
provide a handle greater than 90 and less than 180 degrees to allow
for a comfortable grip of the tool for use in both jigsaw and
reciprocating saw applications.
[0004] Furthermore while conventional drive mechanisms associated
with reciprocating saws are satisfactory for their intended
purpose, a need exists to provide simpler, more durable
alternatives that provide the desired function while advancing the
art.
SUMMARY OF THE INVENTION
[0005] It is a general object of the present invention to provide a
reciprocating saw including a carrier operable to cooperate with a
power source to translate rotational movement of the power source
into reciprocal linear actuation of a saw blade.
[0006] In one form, the present invention provides a reciprocating
saw having a housing containing a motor. A carrier is slidably
disposed within the housing and includes a first portion adapted to
receive a saw blade and a second portion having a slot
therethrough. A rotatable element is fixed for rotation about an
output shaft of the motor. A follower operably interconnects the
carrier and the rotatable element. Rotation of the rotatable
element provides reciprocal linear motion of the carrier. The
follower follows a reciprocal linear path within the slot.
[0007] In another form, the present invention provides a
reciprocating saw including a housing containing a motor. The saw
further includes a saw blade having a cutting edge, a mounting edge
and a side surface, the side surface defining a first plane. A
carrier member is included having a first portion including a base
defining a second plane, the base is adapted to receive the saw
blade wherein the first plane is parallel to the second plane. The
carrier includes a second portion in communication with the motor.
The second portion includes a slot which defines a guide path. A
rotatable element is fixed for rotation about an output shaft which
extends from the motor. A follower operably interconnects the
carrier and the rotatable element. Rotation of the rotatable
element provides reciprocal linear motion of the carrier. The
follower follows a reciprocal linear path within the guide
path.
[0008] In yet another form, the present invention provides a
reciprocating saw including a housing containing a motor. A saw
blade is included having a shank portion and a cutting portion. The
reciprocating saw further includes a carrier having a first portion
adapted to receive a saw blade and a second portion in
communication with the motor. The first portion includes a pair of
lateral walls and a base extending between the walls. A clamp
extends from the lateral walls. The clamp engages the saw blade at
an interface edge to retain a shank portion of the saw blade within
the first portion of the carrier. A cam member extends between the
lateral walls. The cam member is positioned away from the base
portion forming a gap to receive the blade. The cam member is
adjacent a portion of the blade between the interface edge and the
cutting portion.
[0009] In another form, the present invention provides a
reciprocating saw including a housing and a motor. A carrier is
slidably disposed within the housing and includes a first portion
adapted to receive a saw blade and a second portion adapted to
communicate with a motor. A fan is disposed in a handle portion of
the housing and configured to force air through the second portion
of the carrier. Air flows from the second portion of the carrier to
the first portion of the carrier creating a seal to prevent
woodchips and debris from entering the tool.
[0010] In still another form, the present invention provides a
reciprocating saw including a housing and a motor. The housing
includes a primary base having a planar surface for interfacing the
workpiece. The primary base further includes an aperture providing
a passageway for a saw blade. In addition, the primary base
includes a first pair of lateral rails extending outwardly from
opposite sides of the base. A secondary base is provided including
a second pair of lateral rails oriented to slidably engage the
first pair of lateral rails for selectively mounting to the primary
base. The secondary base provides a greater planar surface area for
increased stability during cutting.
[0011] Further areas of applicability of the present invention will
become apparent from the detailed description provided hereinafter.
It should be understood that the detailed description and specific
examples, while indicating the preferred embodiment of the
invention, are intended for purposes of illustration only and are
not intended to limited the scope of the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention will become more fully understood from
the detailed description and the accompanying drawings,
wherein:
[0013] FIG. 1 is a perspective view of the reciprocating saw of the
present invention.
[0014] FIG. 2 is a cutaway view of the reciprocating saw.
[0015] FIG. 3 is a perspective view of the carrier removed from the
saw.
[0016] FIG. 4 is a cutaway view of the saw along line 4-4 of FIG.
2.
[0017] FIGS. 5A-5D is a partial cutaway view of the carrier and
drive assembly through one complete rotation of the output
gear.
[0018] FIG. 6 is a rear perspective view of the reciprocating saw
shown with the secondary base attached.
[0019] FIG. 7 is a perspective view of the reciprocating saw shown
with the secondary base removed to illustrate the rails of the
primary base.
[0020] FIG. 8 is a perspective view of the secondary base.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0021] The following description of the preferred embodiment(s) is
merely exemplary in nature and is in no way intended to limit the
invention, its application, or uses.
[0022] With initial reference to FIGS. 1 and 2, a reciprocating saw
according to the teachings of the present invention is illustrated
and generally identified by reference numeral 10. Reciprocating saw
10 includes a motor 12 disposed within a housing 14. Reciprocating
saw 10 is configured to actuate saw blade 20. Housing 14 includes a
handle 94 extending at an angle greater than 90 degrees with
respect to saw blade 20. Handle 94 preferably extends at an angle
between 105 and 125 degrees to allow for a comfortable grip for use
in jigsaw and reciprocating saw applications.
[0023] With continued reference to FIG. 2, and additional reference
to FIGS. 3 and 4, the blade retaining mechanism 46 will be
described in greater detail. A carrier or shaft 16 actuates a saw
blade 20. The carrier 16 is disposed within the housing 14. The
carrier 16 has a first portion 24 which receives the saw blade 20,
and a second portion 26 which is driven by drive assembly 30. First
portion 24 of carrier 16 incorporates the blade retaining mechanism
46. The blade retaining mechanism 46 includes cam system 28 and
base 42 as described in copending application "Saw Blade Clamp
System" which is hereby incorporated by reference. The cam system
28 includes a rocker arm 32 having a lever end 34, an intermediate
pivot portion 36 and a clamp end 38. The intermediate pivot portion
36 is adapted to receive a support shaft 40. The rocker arm 32
rotates about the support shaft 40. The lever end 34 is activated
by a push button 108 mounted on the housing 14.
[0024] Rocker arm 32 is biased in a clockwise direction (arrow C)
such that the clamp end 38 is influenced against the saw blade 20.
Spring 44 includes spring ends 48 fixedly attached to a first and
second side wall 56, 58 of base 42. An intermediate loop 50 of the
spring 44 is adapted to communicate with an upper surface 54 of the
rocker arm 32 to provide a biasing force.
[0025] First and second side walls 56, 58 extend perpendicularly
from floor 60 of base 42 to define channel 62. Side walls 56, 58
are supported on opposite sides by ball bearings 64, 66 disposed on
guide platform 164 in housing 14 for slidable movement. Ball
bearings 64, 66 are preferably positioned at a location proximate
to the rocker arm 32 and blade 20 interface point to reduce
torquing on the carrier 16 and blade 20 during operation. The
outside cross-section of the carrier 16 is substantially the same
along the length of where the blade 20 is retained. This allows
ball bearings 64, 66 to roll smoothly along surfaces 56 and 58.
Concurrently, ball bearings 64, 66 maintain a proximate relation to
the cutting bias forces created during cutting which minimizes
bearing load. Guide flanges 84, 86 retain bearings 64, 66 and allow
the bearings 64, 66 to be closer to the cutting bias force.
[0026] The first and second side walls 56, 58 include first and
second spring mounting passages 70, 72. The passages 70, 72 fixedly
secure the spring ends 48. Similarly, support shaft 40 is retained
through apertures 74, 76 disposed in walls 56, 58, respectively.
The ends 80, 82 of first and second side walls 56, 58 are contoured
outwardly creating first and second guide flanges 84, 86. A cam
member or pin 90 extends between walls 56, 58. The pin 90 provides
additional support to blade 20 which discourages blade breakage
within the carrier 16 during operation. The guides 84, 86 serve to
help direct the blade 20 into the channel 62. The floor 60 of the
base 42 includes a stop 92. Stop 92 is oriented at an angle toward
the cam system 28.
[0027] Referencing now all Figures, the operation of retaining
mechanism 46 will now be described. To install blade 20 in the
retaining mechanism 46, the blade 20 is inserted into channel 62
until the outer edge 52 of the blade 20 abuts the angled contact
surface 68 of stop 92. Accordingly, the body or major side surface
22 of blade 20 is oriented so that the planar surfaces 22 and 60
are in a parallel or in-line relationship. Thus, as the blade 20
cuts through a workpiece, the material width of the carrier 16 as
well as the blade 20 are in the line of cut. This increases the
blade strength during operation.
[0028] Tail section 78 of blade 20 extends between stop 92 and the
first side wall 56 to provide the blade 20 with additional
stability. Side surface 98 of stop 92 provides a bias against
surface of tail section 78 of blade 20. Once the blade 20 is fully
inserted, spring 44 biases the clamp end 38 against the aperture
wall 18 of the blade 20. The force influences surface 52 against
surface 68 of stop 92 to secure the blade 20 to the blade retaining
mechanism 46. Stop 92 cams blade 20 down against base 42 which
minimizes side to side clearances making the cut more accurate and
efficient. To remove the blade 20, a push button 108 on housing 14
is pressed against the lever end 34 of rocker arm 32 to disengage
the clamp end 38 from the aperture wall 18 of the blade 20.
[0029] The second portion 26 of the carrier 16 includes an outer
flange 100 extending from first and second walls 56, 58 around the
perimeter of first portion 24. Likewise, base 42 of first portion
24 extends to second portion 26 and is bordered by flange 100. Slot
102 is integrated into base 42. Slot 102 is defined by a first and
second pair of lateral walls 104, 106 extending from opposing edges
of the slot 102. Lateral wall sections 104, 106 define a guide path
110. Slot 102 further includes opposing channels 114, 116 formed in
base 42 of carrier 16. The channels 114, 116 are formed between
first and second pair of lateral wall sections 104, 106. As will be
described in detail, opposing channels 114, 116 are configured to
accommodate gear support shaft 120. The opposite ends of guide path
110 are defined by grooves 122, 124.
[0030] Turning now to FIGS. 2-4, the drive assembly 30 will be
further described. The drive assembly 30 is initiated by actuation
of trigger 96 extending from housing 14. Motor 12 includes drive
gear 88 which is splined for rotation with output gear 124. Drive
assembly 30 includes gear support shaft 120 supported at opposite
ends by bearings 140, 142. Gear noise and wear are reduced by
supporting shaft 120 at opposite ends. Output gear 124 is disposed
on support shaft 120. An offset output shaft 130 is coupled to
output gear 124. The output shaft 130 is arranged to orbit drive
shaft 130. A follower 134 is rotatably coupled to offset output
shaft 130. Follower 134 includes roller 136 and slider 138 which
are received within guide path 110 of slot 102. As such,
translation of follower 134 along guide path 110 encourages
concurrent rotatable engagement of roller 136 and slidable
engagement of slider 138 along the face of the corresponding
lateral walls 104, 106. The advantage of using follower 134
including roller 136 and slider 138 is that it provides reduced
gear noise and wear while providing low output shaft 130
losses.
[0031] Turning to FIGS. 5A-5D, during operation, carrier 16 makes a
generally reciprocal up and down linear motion as designated by
arrow "A". FIG. 5A represents the follower 134 in a top dead center
position with respect to slot 102. FIG. 5B shows the follower at 90
degrees fully extended in the horizontal position. FIG. 5C
represents the follower in a bottom dead center position at 180
degrees. FIG. 5D shows the follower at 270 degrees in a fully
extended horizontal position.
[0032] The rotational motion of drive gear 88 is transmitted
through output gear 124 and associated orbit drive shaft 130 to
follower 134. Rotational movement of output gear 124 is designated
by arrow "B". Slot 102 within carrier 16 converts the vertical
component of the circular path of the orbit drive shaft 130 into up
and down linear motion of carrier 16. The horizontal component of
the circular path is expended as the orbit drive shaft 130 moves in
the direction of guide path 110. The opposing channels 114, 116
integrated on carrier 16 provide a passage to accommodate gear
support shaft 120 as the follower 134 transmits through the
horizontal component of the circular path (FIGS. 5A and 5C).
Accordingly, slider 138 has a width "W", which extends in the
direction of guide path 110, a distance greater than the width "X"
of channels 114, 116. Such a relationship minimizes momentum loss
of the follower 134 while travelling past channels 114, 116 to
provide smooth transition in the horizontal direction. In addition,
roller 136 increases efficiency of the reciprocating movement of
follower 134. This is due to the fact that the majority of the
movement is accomplished by the roller 136 rolling on the lateral
walls 104, 106.
[0033] Returning to FIGS. 2 and 3, the reciprocating saw 10
includes a fan 17 disposed within the handle 94 and oriented to
force air around motor 12 to second portion 26 of carrier 16. The
fan 17 is arranged to provide cooling to motor 12 and inhibit
debris from collecting around cam system 28 and drive assembly 30.
A portion of the air escapes the housing 14 through vents 150
incorporated on opposite sides of the housing 14. The remaining
airflow is directed from second portion 26 to first portion 24
through channel 62 of carrier 16. The airflow through channel 62
acts as a seal to inhibit woodchips and other debris from settling
around retaining mechanism 46. The residual air flowing through
channel 62 clears debris away from the blade 20, workpiece
interface which improves visibility. The airflow also creates a
positive pressure away from second portion 26 of carrier 16 to
discourage debris from settling around the drive assembly 30.
[0034] Turning to FIGS. 6-8, the reciprocating saw 10 includes a
primary and secondary base 144, 154. Primary base 144 includes heal
portions 146 and lateral rails 148 extending from opposite edges to
provide stability during operation. Secondary base 154 includes a
second pair of lateral rails 156 inwardly extending from outer
walls 158. Secondary base 154 is selectively attachable to primary
base 144 to provide greater surface area and stability during
operation. A latch 160 is mounted to primary base 144 and provided
for coupling the secondary base 154 with the primary base 144 in an
engaged position. A button 162 of the latch 160 is configured to
extend through an opening 166 in the housing 14 to improve
accessibility. The latch 160 maintains a static position in the
tool assembly by a compression spring (not shown). The spring acts
along its axis between sidewall 174 of button 162 on one end and an
interior wall (not shown) of primary base 144 on the opposite end
which forces the latch 160 into engagement with the contact wall
182 of stop 172.
[0035] To install secondary base 154 onto primary base 144, the
first pair of rails 148 of the primary base 144 are aligned with
the second pair of rails 156 on the secondary base 154. The
secondary base 154 is moved forward in a direction parallel to the
axis of the rails 156. The button 162 of latch 160 is depressed
until wall 172 of stop 170 extending from the secondary base 154
engages wall 176 of the primary base 144. The button 162 of latch
160 is then released causing arm 178 of latch 160 to be received
through passage 184 in stop 170. Engagement of arm 178 with lip 182
of stop 170 ensures secondary base 154 is locked into position.
[0036] While the invention has been described in the specification
and Illustrated in the drawings with reference to a preferred
embodiment, it will be understood by those skilled in the art that
various changes may be made and equivalents may be substituted for
elements thereof without departing from the scope of the invention
as defined in the claims. Accordingly, it is intended that the
invention not be limited to the particular embodiment illustrated
by the drawings and described in the specification as the best mode
presently contemplated for carrying out this invention, but that
the invention will include any embodiments falling within the
description of the appended claims.
* * * * *