Components having sharp edge made of sintered particulate material

Abstract

Safety chain and rotatable devices for saws include a plurality of base members on which sharp members are retained. The sharp members include sintered particulate material such as tungsten carbide, which has high particle hardness. The base members are formable from sintered particulate material. The sharp members to be formed by powder metal molding, metal injection molding or investment casting to provide the protrusion and recess with a final net shape. The cutting member is one, two or more pieces, and is permanently bonded to or removably disposed on the base member. Bonding material or fasteners can connect the cutting member to the base or a tip to an insert body; bonding material includes cement, solder, braze and polymer. Safety lobes prevent the teeth from being dislodged. Devices include dado blade, planer blade and bandsaw blade, chain saw, buck saw, rescue saw, automated wood cutting apparatus, circular saw, saw blade, knife, scissors, shears, grass cutter, weed cutter, grass cutting blade and weed cutting blade.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of saw chain constructed in accordance with the present invention;

FIG. 2 is an exploded view of the saw chain of FIG. 1;

FIG. 3 is a side elevational view of the saw chain of FIG. 1;

FIG. 4 is a top plan view of the saw chain as seen along the lines and arrows designated 4-4 in FIG. 3;

FIG. 5 is a vertical cross-sectional view as seen along the lines and arrow designated 5-5 in FIG. 3;

FIG. 6 is a perspective view of one of the holding links and teeth;

FIG. 7 is a side elevational view of the saw chain of FIG. 1 showing how a safety lobe of an upstream link can be rotated out of the path of a tooth for removal and replacement of the tooth;

FIG. 8 is a perspective view showing another aspect of the inventive saw chain wherein the safety links include rakers;

FIG. 9 is an exploded view of the saw chain shown in FIG. 8;

FIG. 10 is a side elevational view of a portion of the saw chain shown in FIG. 8;

FIG. 11 is a perspective view of a portion of saw chain featuring another aspect of the present invention wherein one of the links includes a safety cam member that retains the tooth on the holder;

FIG. 12 is an exploded view of the components of the chain shown in FIG. 11;

FIG. 13 is a side elevational view of the saw chain shown in FIG. 11;

FIG. 14 is a side elevational view of the saw chain shown in FIG. 13 showing how the safety cam and safety lobe are rotated out of the path of the tooth permitting its removal and replacement;

FIG. 15 is a side elevational view of a rotational cutting device constructed in accordance with the present invention;

FIG. 16 is an enlarged view of a portion of the device shown in FIG. 15;

FIG. 17 is a cross-sectional view taken along lines and arrows 17-17 in FIG. 15;

FIG. 18 is an enlarged perspective view of the device shown in FIG. 15;

FIG. 19 is an exploded view of the device shown in FIG. 18;

FIGS. 20-22 illustrate saw chain including teeth adapted for abrasion of material;

FIGS. 23-27 illustrate replaceable teeth adapted for cutting material, used in the saw chain of FIGS. 1-10;

FIGS. 28 and 29 feature another embodiment of the present invention including tipped tooth inserts and optional safety lobes;

FIG. 30 is a side view showing tipped inserts constructed in accordance with the present invention;

FIGS. 31-33 feature inventive tipped inserts in which the tips are rigidly connected to the insert bodies using fasteners;

FIGS. 34-36 feature inventive tipped inserts in which the tips are rigidly connected to the insert bodies using bonding material;

FIG. 37 shows how the tipped insert is kept from being dislodged from the chain using a safety lobe;

FIGS. 38 and 39 show blades including tipped inserts that prevent them from being dislodged via safety lobes on the other blade;

FIGS. 40A-C show an assembled die constructed in accordance with the present invention;

FIGS. 41A and 41B show a part cavity in the die and another cavity for receiving a support member that positions the core pin in a desired location in the cavity;

FIGS. 42A-C show various views of a lower die section;

FIGS. 43A-C show various view of an upper die section;

FIGS. 44A-C feature an upper punch constructed in accordance with the present invention;

FIGS. 45A and 45B feature a lower punch constructed in accordance with the present invention;

FIGS. 46A and 46B feature an upper clamp constructed in accordance with the present invention;

FIGS. 47A and 47B feature a lower clamp constructed in accordance with the present invention;

FIG. 48 shows an integral one-piece cutting link constructed in accordance with the present invention;

FIG. 49 shows a representative blade (e.g., bandsaw) and how tooth inserts are inserted on the blade in accordance with the present invention; and

FIGS. 50 and 51 show scissors and knife that include components constructed in accordance with the present invention.

Claims

1. Carbide saw chain comprising: a plurality of links including drive links, cutting links and tie straps that are pivotally interconnected by rivets; andwherein said cutting links include a base member comprised of sintered particulate metal material and a cutting member comprised of sintered particulate metal material that includes carbide, said cutting member includes a sharp cutting edge, said base member includes holes for receiving the rivets, and one of said base member and said cutting member includes a first projecting seat surface and the other of said base member and said cutting member includes a second recessed seat surface configured to receive said first seat surface.

2. The carbide saw chain of claim 1 comprising a bonding material between said first and second seat surfaces selected from the group consisting of cement, braze, solder, polymer and combinations thereof.

3. The carbide saw chain of claim 2 wherein said cutting member and said base member are formed by a process that provides said first seat surface and said second seat surface with a final net shape and sharp said cutting edge.

4. The carbide saw chain of claim 3 made by a process selected from the group consisting of powder metal molding, metal injection molding, investment casting and combinations thereof.

5. The carbide saw chain of claim 2 wherein said cutting member and said tie straps are disposed on sides of the chain and the drive links are disposed at a center of the chain.

6. The carbide saw chain of claim 5 wherein said base member includes a body portion extending to a height of said tie straps along the chain and said first seat surface is part of said base member and located above said body portion.

7. The carbide saw chain of claim 6 wherein said first seat surface is a key formed on said base member and said second seat surface is a keyway formed in said cutting member.

8. The carbide saw chain of claim 7 wherein said key and said keyway are untapered.

9. The carbide saw chain of claim 7 wherein said key and said keyway have an inverted L-shape.

10. The carbide saw chain of claim 1 wherein said cutting member is separate from said drive link.

11. The carbide saw chain of claim 1 wherein said cutting member includes a cutting insert comprised of the sintered particulate metal material adapted to be removably disposed on said base member, and a cutting tip comprised of sintered particulate metal material including carbide, said cutting tip including a sharp cutting edge.

12. The carbide saw chain of claim 11 wherein one of said cutting insert and said cutting tip includes a protrusion and the other of said cutting insert and said cutting tip includes a recess configured to receive said protrusion, and said cutting insert and said cutting tip are rigidly connected to each other.

13. The carbide saw chain of claim 12 wherein there is no fastener for preventing said cutting insert from being removed from said base member in a direction of chain travel.

14. The carbide saw chain of claim 12 wherein said rigid connection includes bonding material selected from the group consisting of cement, braze, solder, polymer and combinations thereof.

15. The carbide saw chain of claim 12 wherein said cutting member and said cutting tip are formed by a process that provides them with a final net shape and sharp said cutting edge.

16. The carbide saw chain of claim 15 made by a process selected from the group consisting of powder metal molding, metal injection molding, investment casting and combinations thereof.

17. The carbide saw chain of claim 11 wherein said cutting member is separate from said drive link.

18. The carbide saw chain of claim 12 wherein said base member includes a body portion extending to a height of said tie straps along the chain, further comprising a depth gauge located upstream of said cutting tip.

19. The carbide saw chain of claim 12 wherein said base includes a key and said cutting member includes interior walls that form a keyway configured to receive said key.

20. The carbide saw chain of claim 18 wherein said key and said keyway are untapered.

21. The carbide saw chain of claim 11 wherein said cutting tip has front and rear portions, said cutting edge is disposed near said front portion, one of said protrusion and said recess is disposed near said rear portion of said cutting tip, and said cutting insert includes the other of said protrusion and said recess disposed near a front portion of said cutting insert.

22. The carbide saw chain of claim 20 wherein an internal surface of said cutting tip forms a through-hole extending from said front portion of said cutting tip to said rear portion of said cutting tip and said rigid connection between said cutting tip and said cutting insert is formed by bonding material disposed in said through-hole and said recess.

23. The carbide saw chain of claim 21 wherein said bonding material is selected from the group consisting of cement, braze, solder, polymer and combinations thereof.

24. The carbide saw chain of claim 20 wherein an internal surface of said cutting tip forms an interiorly unthreaded through-hole extending from said front portion of said cutting tip to said rear portion of said cutting tip and an interiorly threaded opening extends from a front portion of said cutting insert into an interior of said cutting insert in alignment with said through-hole, including a fastener threaded into the through-hole and said opening.

25. The carbide saw chain of claim 11 wherein said cutting links include a base member comprised of sintered particulate metal material, a one-piece cutting insert comprised of sintered particulate material including carbide, said cutting insert being adapted to be removably disposed on said base member, said cutting insert including a sharp cutting edge, said base member including holes for receiving the rivets; and a safety lobe located in proximity to said cutting insert that prevents dislodging of said cutting insert in a direction of travel of the chain.

26. The carbide saw chain of claim 25 wherein said safety lobe extends from a link that is located upstream of said cutting link.

27. The carbide saw chain of claim 25 comprising a depth gauge located upstream of said cutting insert, said safety lobe being disposed between said depth gauge and said cutting insert at all positions of the chain during a cutting operation.

28. Carbide saw chain comprising: a plurality of links including drive links, cutting links and tie straps, which are pivotally interconnected by rivets;wherein said cutting links include a base member, a cutting insert comprising sintered particulate metal material, said cutting insert being adapted to be removably disposed on said base member, and a cutting tip including a sharp cutting edge and being comprised of sintered particulate carbide material, said base member including holes for receiving the rivets;wherein one of said cutting insert and said cutting tip includes a protrusion and the other of said cutting insert and said cutting tip includes a recess configured to receive said protrusion, said cutting tip being rigidly connected to said cutting insert;wherein one of said cutting insert and said base member includes a first projecting seat surface and the other of said cutting insert and said base includes a second recessed seat surface configured to receive said first seat surface;a safety lobe located in proximity to said cutting insert that prevents dislodging of said cutting insert in a direction of travel of the chain, wherein said safety lobe extends from a link that is located upstream of said cutting link; anda depth gauge located upstream of said cutting insert.

29. The carbide saw chain of claim 28 wherein said base member comprises sintered particulate metal material.

30. The carbide saw chain of claim 28 wherein said cutting member is separate from said drive link.

31. The carbide saw chain of claim 28 wherein said base member is comprised of steel and includes said first seat surface.

32. The carbide saw chain of claim 28 wherein said cutting insert, said cutting tip and said base member are formed to provide them with a final net shape and said sharp cutting edge.

33. The carbide saw chain of claim 28 wherein said cutting tip has front and rear portions, said cutting edge is disposed near said front portion, and one of said protrusion and said recess is disposed near said rear portion of said cutting tip, and said cutting insert includes the other of said protrusion and said recess disposed near a front portion of said cutting insert.

34. A component with high hardness sharp member formed of sintered particulate material, comprising: a first base member,a second member comprised of sintered particulate material adapted to be disposed on said base member, said second member including a sharp edge, the particulate material of said second member having a particle hardness of at least 65 Rockwell C;wherein one of said second member and said first base member includes a protruding first seat surface and the other of said second member and said first base member includes a second recessed seat surface configured to receive said first seat surface; andwherein said second member is formed to have a final net shape and said sharp edge.

35. The component of claim 34 wherein said protrusion and said recess are bonded together with a material selected from the group consisting of cement, solder, braze, polymer and combinations thereof.

36. The component of claim 34 wherein said material includes tungsten carbide.

37. The component of claim 34 wherein said material includes STELLITE™ brand material.

38. The component of claim 34 wherein said base member is comprised of steel.

39. The component of claim 34 wherein said second member is comprised of ceramic.

40. The component of claim 34 wherein said first base member is comprised of metal and said second member is comprised of ceramic, including a ceramic-metal bonding material rigidly connecting said second member to said base member.

41. The component of claim 34 comprising a rigid body in the shape of a circular plate, and a plurality of said first members protruding from said plate along a peripheral edge thereof.

42. The component of claim 41 wherein said second member comprises an insert adapted to be removably disposed on said base and a tip that are formed of sintered hard particulate material, one of said tip and said second insert including a protrusion and the other of said tip and said insert including a recess adapted to receive said second protrusion.

43. The component of claim 41 wherein said second member includes a tip formed of carbide and said first seat surface of said base member is steel machined to form said second seat surface, said second member being rigidly connected to said base by a bonding material selected from the group consisting of cement, solder, braze, polymer and combinations thereof.

44. The component of claim 34 in the form of a knife, wherein said first base member is a knife handle and said second member includes a sharp edge on an end of said handle.

45. The component of claim 44 wherein said second member includes an insert and a tip that are formed of sintered particulate material, said insert being adapted to be removably connected to said first member and one of said tip and said insert including a protrusion and the other of said tip and said insert including a recess adapted to receive said protrusion.

46. The component of claim 45 wherein said tip includes one of a variety of knife edge sizes and shapes.

47. The component of claim 45 wherein the particulate material of said tip has a particle hardness of at least 65 Rockwell C.

48. The component of claim 44 wherein said first member includes one of a variety of knife handle shapes and sizes, and handle materials.

49. A blade including the component of claim 34 selected from the group consisting of: dado blade, planer blade and bandsaw blade.

50. A device that includes the component of claim 34, selected from the group consisting of: chain saw, buck saw, rescue saw, automated wood cutting apparatus, circular saw, saw blade, knife, scissors, shears, grass cutter, weed cutter, grass cutting blade, weed cutting blade and combinations thereof.

51. A one-piece cutting link for saw chain comprised of sintered particulate material, wherein said link includes rivet holes, a body and a cutting edge disposed above said body.

52. The cutting link of claim 51 wherein said sintered particulate includes a material selected from the group consisting of: metal, ceramic, composites and combinations thereof.

53. The cutting link of claim 51 wherein a member of said cutting link includes a porosity that captures lubricant.

54. The cutting link of claim 51 wherein said cutting link has a density approximating theoretical density.

55. A method of manufacturing a component comprised of sintered particulate material comprising: providing a die having a cavity therein;positioning a removable core pin in said cavity;positioning a first punch having a recess corresponding to the shape of the core pin, around the core pin in the cavity, at a location short of an end of the core pin;feeding particulate material into the die around the core pin and onto an internal surface of the first punch;providing a second punch with a configuration effective to provide a sharp edge to a portion of a part being manufactured;moving the first punch and the second punch toward each other inside the die cavity by a predetermined distance that is effective to provide the part with suitable density; andwherein the part has a first sharp edge formed by the second punch and a blind keyway that is formed by the core pin and first punch.

56. The method of claim 55 wherein one of said first punch and said second punch is removed from the die and the other punch moves to eject the component from the die.

57. The method of claim 55 comprising removing a worn core pin from the die and replacing the worn core pin with another core pin.

58. The method of claim 55 comprising removing the second punch from the die after forming the part and raising the first punch to eject the part from the die.

59. The method of claim 55 comprising sintering the parts in a furnace.

60. The method of claim 59 comprising grinding the part to provide a sharp edge.