Patent Application
20110072944
1. Field of the Invention
The present invention relates generally to saws, blades and other cutting tools. In particular the present invention relates to flexible linked cutting systems.
2. Description of the Related Art
Flexible cutting apparatus can be used in various types of cutting tools, including band saws, chain saw, wire saws, and cable saws. Flexible cutting apparatus can be described as blades, wires, chains, cables, etc. Each of these may include teeth, or other hard surfaces designed to cut. Cutting can include rough or fine cuts, sawing, scraping, honing, abrading, shaving, grinding, etc. Many cutting and abrading applications have benefited from these various available flexible cutting apparatus.
As an example of a flexible cutting apparatus, cable saws generally use a continuous cable with cutting or abrading beads. The beads may be strung onto or directly attached to the cable. Where the beads are strung onto the cable there may also be spacers in-between the cutting beads.
The thickness of the wire used often depends on the application or the object to be cut. As the thickness and strength of the wire increase, so does the stiffness. For example, a cable saw used for mining operations is likely to use a wire or braided cable thicker than the wire used to cut glass or to cut a silicone wafer.
There exists a continuing need to develop stronger and more flexible cutting apparatus. Along with this need, there also exists a need to develop new designs for cutting tools to facilitate the use of the new flexible cutting apparatus.
Embodiments disclosed herein include a cutting system that can comprise a plurality of first links, a plurality of second links, and a plurality of cutting beads. The each of the plurality of first links can include a first end, a second end, and a central portion connecting the first end and the second end. Each of the plurality of second links can include an external surface, and an internal surface. At least one of the first end and the second end of one of the plurality of first links can form a joint with the internal surface of each of the second links. Also, each cutting bead can be connected to the external surface of one of the plurality of second links.
The cutting system can comprise an alternating configuration of one of the plurality of first links and one of the plurality of second links, wherein each of the plurality of second links and the connected cutting beads are configured to freely rotate independent of the position of the other links. The cutting system can further include ball and socket joints and/or be self-lubricating. In some embodiments, each of the plurality of second links comprises two connecting portions that define the external surface and the internal surface.
In certain embodiments, a cutting system can comprise a plurality of first links, a plurality of second links, and a plurality of cutting beads. Each first link can have ball ends and a shaft connecting the ball ends. Each second link can have a first end inside surface configured to form a ball and socket joint with one of the ball ends of one of the plurality of first links and a second end inside surface configured to form a ball and socket joint with one of the ball ends of another one of the plurality of first links. Each cutting bead can be configured to connect to an outside surface of one of the plurality of second links.
The second links may further comprise first and second portions that when connected form a chamber inside the second link and define the inside surfaces of the first end and the second end. It can also include an interlocking feature to interlock the portions, and/or a restraining feature to prevent separation of the cutting bead from the outside surface of the second link.
The cutting system can further comprise lubricant within the chamber in each of the plurality of second links. In use, the internal chamber of each of the plurality second links can be substantially sealed so that the cutting system is self-lubricating.
In some embodiments, a cutting system can comprise a fluid channel and a vacuum conduit. The cutting system can be configured to direct fluid through the fluid channel at a plurality of first and second links and cutting beads, to thereby clean off and remove debris from a cutting action of the plurality of cutting beads. The vacuum conduit can be positioned and configured to remove the fluid and the debris. The system can further comprise a cog for engaging the plurality of first and second links and cutting beads. The cog can have internal piping to direct the fluid at areas of the plurality of first and second links and cutting beads engaged with the cog.
Embodiment of a cutting device can comprise a plurality of main bodies linkedly connected in series along an axis and a plurality of generally cylindrical cutting surfaces. The cutting surface can be configured to surround a portion of one of the plurality of main bodies. The cutting device can be configured to support a tension along a length of the cutting device. The plurality of cutting surfaces can be configured to independently rotate about their respective axes.
In order to better understand the invention and to see how it may be carried out in practice, some preferred embodiments are next described, by way of non-limiting examples only, with reference to the accompanying drawings, in which like reference characters denote corresponding features consistently throughout similar embodiments in the attached drawings. Where a prime symbol (′) has been added to the numerical reference, it is to be understood that the components are the same or substantially similar to previously-described components.
A flexible cutting apparatus can be used in a cutting tool for many different applications. Shown in
In some embodiments, two or more different types of links can be used. The arrangement of links can be an ordered pattern and/or a random configuration. In some embodiments, only one type of link is used. The link can both connect to other links and can be used to cut material.
As will be described in more detail below, the second link 4 can include a cutter 6 which may comprise at least one of a blade, a cutting bead, a hard surface, a tooth, etc. In some embodiments such as the one illustrated, the cutter 6 can comprise a cutting bead with a plurality of cutting teeth 8 that surround the second link 4.
Turning now to
Also shown is a central portion or shaft 23. The central portion 23 can connect the two ends 21. The size and shape of the central portion 23 can depend on various factors. For example, the desired clearance between where the different links connect, the desired length between cutters, and the desired length of the flexible cutting apparatus 10 can all be factors used to determine the shape and size of the connecting region 23. Another consideration can be the desired minimum diameter for the flexible cutting apparatus 10 around a cog or gear. So for example, to increase the flexibility of the flexible cutting apparatus 10, the outer dimensions of the central portion 23, here the outer diameter, can be less than the outer dimensions of the ends 21. This can allow the other link, connected to the end 21, to have a large range of motion about the connection point or joint.
One or more of the ends 21 can be shapes other than balls to form a connection point or joint similar to or different from a ball and socket joint. For example, one or more of the ends 21 can be round, semispherical, spherical, elliptical, oval, conical, triangular or pyramidal. The ends 21 can be keyed or shaped to form part of a hinge or other moveable joint. As shown in
The first link 2 can be manufactured according to many different methods. In a preferred embodiment the first link 2 is cast, but it can also be extruded, stamped, milled, etc. The first link 2 can be made from titanium, high grade steel, steel, various alloys, high strength polymer, carbon fiber, etc. In some embodiments, the first link 2 comprises a central portion 23 formed of cable or wire, such as a multi-strand steel cable. The ends 21 can be steel balls, or other shapes and materials, that are clamped, crimped or otherwise secured to the central portion 23 whether by mechanical devices or adhesive/epoxy. In still other embodiments, the cable or wire is formed to provide ends 21 that can be used to attach the first link 2 to other links without adding additional material. The central portion 23 can be flexible or rigid.
The portion 12 can form all or part of the internal chamber 14 of the second link 4. The portion 12 can form all or part of a first hole 16 and a second hole 18. The first and second holes 16, 18 can be configured to accommodate the central portion 23 of the first link 2. The particular dimensions, or in this case diameter, of the holes 16, 18 can be chosen based on many different factors, such as the shapes and sizes of the end 21 and central portion 23 of the first link 2, the amount of desired clearance or rotation allowed between the links when connected, the stress loads expected to be experienced at the joint or connection, etc. In a preferred embodiment, the dimensions of the holes 16, 18 are less than the largest outer dimension of the end 21 of the first link and greater than the largest dimension of the central portion 23 immediately adjacent to the end 21.
According to certain embodiments, the second link 4 can have an interlocking feature 20 (
In some embodiments, the interlocking feature 20 can include a protrusion 24 and a groove 22. The protrusion 24 can be configured to fit in the groove 22. In some embodiments, the protrusion 24 and groove 22 form a friction fit to secure two portions 12 together. In some embodiments, an adhesive or epoxy is used to secure the portions 12 together, independent of whether the second link 4 includes an interlocking feature 20, and independent of whether the interlocking feature 20 forms a tight or loose connection. In some embodiments, the portions 12 are welded together. For example, a spot weld can be made anywhere along a connecting seam between the connected portions 12.
The second link 4 may further include a sleeve (not shown). The sleeve can secure the two or more portions together. In some embodiments, the sleeve comprises an epoxy which welds or secures the portions 12 together.
Referring now to
As mentioned above, the second link 4 can include a cutter 6. The cutter 6 can be part of the second link 4 or can be a separate piece. For example, in some embodiments, the cutter 6 can comprise part of the first link 2, the second link 4 or a different link (not shown). In some embodiments, the cutter 6 can be part of one or more portions 12 of the second link 4. The cutter 6 can comprise at least one of a blade, a cutting bead, a hard surface, a tooth, etc.
Looking to
The plurality of cutting teeth 8 can surround the cutter 6 as shown, but can also be in specific regions or areas of the cutter 6. For example, some embodiments have only one cutting tooth 8, or one or more cutting teeth 8 on one or more sides of the cutting bead 34. The cutting teeth 8 can also be angled.
In some embodiments, the angle 40 can be between 1 and 45 degrees. In some embodiments, the angle 40 can be between 2 and 12 degrees or between 2 and 3 degrees. The angle 40 can depend on many features such as the material to be cut and the amount of friction desired to rotate the cutter 6.
The assembly of one embodiment of a flexible cutting apparatus 10 will now be explained.
The cutting bead 34 can rotate with the second link 4. The teeth on the cutting bead 34 can be configured and shaped to rotate the cutting bead about its axis while cutting. For example, the teeth can be angled as discussed previously, which can cause the cutting bead 34 to rotate as it cuts through a piece of material.
Rotating cutters can provide many benefits. For example, the rotation can allow multiple teeth on each cutter 6 to participate in the cut allowing the cutter to provide a smoother and cleaner cut. The rotation can also help prevent the cutting tooth from breaking if a different or difficult to cut material is encountered. For example, a cutting tool used to cut plant material that does not rotate may be broken off or damaged if a rock is encountered. A cutting tool using a flexible cutting apparatus that rotates can avoid forcing the cutting tooth directly into the rock both because of the flexibility and the rotation of the apparatus, thereby reducing the likelihood of breakage or damage.
The flexible cutting apparatus 10 can be internally lubricated. In some embodiments, the method of assembly can include a step of injecting or inserting a lubricant into the internal chamber 14 of the second link 4. In some embodiments, silicone with a lubricant or another material can be injected or inserted into the internal chamber 14. The silicone or other material can also help to maintain the position of the ends 21 within the second link 4. For example, silicone can help keep the ends 21 from contacting one another.
The internal chamber 14 can be ceramic coated or have another or additional coating. The coating can assist with or can provide lubrication. The ends 21 of the first link can also be coated with a ceramic and/or other coating.
The internal chamber 14 can be essentially sealed. The ends 21 can seal the holes 16, 18 in the second link 4.
With a sealed internal chamber 14 and lubricant inside the internal chamber 14, the flexible cutting apparatus 10 can be self lubricating. This can be very advantageous as certain currently available flexible cutting apparatus 10 such as typical used in chainsaws require continual and constant re-lubrication. Chainsaws typically have a reservoir that continually lubricates the chain. A self lubricating flexible cutting apparatus 10 may not require continual re-lubrication or a reservoir for that purpose, though one can be provided for certain applications.
In some embodiments, the second link 4 can include a port for inserting or injecting a lubricant or other material before or after the portions 12 have been connected and sealed.
As shown, the second link 4 has a flange 26 at one end. The cutter 6 can be slid over the second link 4 until an end of the cutter 6 abuts the flange 26. This can provide the proper contact between the second link 4 and the cutter 6. In addition, a configuration of this type can help the cutter 6 to maintain the proper connection with the second link 4 while the apparatus is in use. Advantageously, the rotation of the flexible cutting apparatus 10 can be such as to force the end of the cutter 6 against the flange 26, instead of forcing them apart. This can help the cutter 6 to maintain its connection with the second link 4.
The cutter 6 can also be shaped to correspond to a portion of the outer surface 44 of the second link 4 (
In other embodiments, other links can also be connected to either of the first or second link 2, 4. Depending on the application and the design of the cutter 6, careful attention should be paid to the orientation of the cutter 6. For example, as shown in
In certain embodiments, the method can further include attaching the various components with an adhesive. For example, the portions 12 can connect together with the assistance of an adhesive, the second link 4 and the cutter 6 can connect with adhesive, etc. These connections can also be press or friction fits.
Various other embodiments and variations of the above are also envisioned. For example, in certain embodiments, a chain comprises a first link 2 and a second link 4 without a cutter 6. In other embodiments, the second link 4 and the cutter 6, such as a cutting bead 34, are attached to a continuous or segmented cable or wire. The second link can clamp onto the wire and the cutter 6 can secure the second link 4 in place on the wire.
In some embodiments, the cutter 6 can rotate on the flexible cutting apparatus 10. In some embodiments, the cutter 6 can fit over the second link 4 but does not form a friction or press fit; rather, the cutter 6 can rotate over the second link 4. Referring to
In some embodiments, one or more ball bearings can be used to allow the cutter 6 to rotate. For example, referring back to
Structures consistent with the teachings contained herein, when driven by appropriate drive and guide mechanisms, can be used to cut a wide variety of materials, in a wide variety of configurations. In a preferred embodiment, the flexible cutting apparatus 10 is used in a cutting tool to trim plant material such as trimming leaves of palm trees. In another preferred embodiment, the cutting tool is a surgical cutter used to cut bone.
The cutting tool 50 can include a motor 54 that can drive a main cog 56. The main cog 56 drives the flexible cutting apparatus 10. In some embodiments, the cutting tool 50 can also comprise at least one of a fluid source 58 and a vacuum source 60. The fluid source 58 can provide fluid for many purposes such as lubrication, cooling, cleaning, and other purposes. Fluid can be directed from the fluid source 58 through one or more fluid channels to parts of the cutting tool 50, flexible cutting apparatus 10 and/or the material being cut. The vacuum source 60 can be used to remove undesired debris or other material through a vacuum conduit 72 and from the cutting tool 50, flexible cutting apparatus 10, and/or the material being cut.
In some embodiments, the cutting tool 50 can be configured to direct fluid from the fluid source at the flexible cutting apparatus 10 to thereby clean off and remove any debris from a cutting action of the flexible cutting apparatus 10. The vacuum source 60 can be positioned and configured to further remove the fluid and the debris from the flexible cutting apparatus 10.
Looking now at
In some embodiments, the fluid comprises at least one of high pressure air, water, saline, and pesticide. In some embodiments, there are one or more different fluids. For example, water can be directed at the flexible cutting apparatus 10 in the main cog 56 and pesticide can be directed into a cut created by the cutting tool 50.
Embodiments consistent with the principles disclosed herein can provide many benefits. In the design of flexible cutting apparatus there is a tradeoff between flexibility and strength. Stronger, stiffer flexible cutting apparatus can be extremely heavy-duty, but less flexible than those designed with the opposite tradeoffs. Flexibility translates into tighter possible turning radiuses around smaller guide and drive wheels, permitting an overall smaller saw.
A flexible cutting apparatus as disclosed herein can have increased strength, more flexibility, and versatility over other designs. For example, a flexible cutting apparatus 10 having first and second links connected with ball and socket joints can have significant increased strength and can be used on a cutting tool with smaller turn radius than similarly sized tools.
In addition, a flexible cutting apparatus 10 as disclosed herein can be quite strong and still provide a high degree of effective flexibility due to a close-fit ball and socket connection. A flexible cutting apparatus 10 as disclosed herein can also provide stiff components but be flexible once assembled.
Other benefits of the flexible cutting apparatus 10 can include less breakage, cleaner cuts, and decreased maintenance costs. The linkages and/or cutters can be individually replaceable. Also as discussed above, flexible cutting apparatus 10 can be self-lubricating and therefore does not require additional lubrication.
Although this invention has been disclosed in the context of certain preferred embodiments and examples, it will be understood by those skilled in the art that the present invention extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses of the invention and obvious modifications and equivalents thereof. In particular, while the present flexible cutting apparatus and cutting tools have been described in the context of particularly preferred embodiments, the skilled artisan will appreciate, in view of the present disclosure, that certain advantages, features and aspects of the flexible cutting apparatus and cutting tools may be realized in a variety of other applications, many of which have been noted above. Additionally, it is contemplated that various aspects and features of the invention described can be practiced separately, combined together, or substituted for one another, and that a variety of combination and sub-combinations of the features and aspects can be made and still fall within the scope of the invention. Thus, it is intended that the scope of the present invention herein disclosed should not be limited by the particular disclosed embodiments described above, but should be determined only by a fair reading of the claims.
