Stone working – Sawing – Rotary
Reexamination Certificate
1998-04-06
2001-08-14
Rose, Robert A. (Department: 3723)
Stone working
Sawing
Rotary
C451S542000, C451S546000
Reexamination Certificate
active
06273082
ABSTRACT:
BACKGROUND OF THE INVENTION
It is well known in the abrasive cutting arts related to such materials as concrete, stone, ceramic, glass, composite materials and the like to utilize cores, such as disks for circular saws and disk grinders, cylinders for core drills, bands for band saws and belt grinders, articulating links for a saw chain, solid rectangular metal strips for reciprocating saws, flexible cable for wire-type saws; and to randomly affix a plurality of diamonds or other hard abrasive particles directly to specific areas of the cores, or affix a plurality of cutting members to specific areas of the cores.
1. Field of the Invention
This invention relates generally to cutting tools, and is more particularly concerned with cutting tools that utilize abrasive particles to effect the cutting action.
2. Description of the Prior Art
The prior art cutting members typically comprise a matrix material having a plurality of diamonds or other hard abrasive particles randomly or selectively embedded therein. It is also known to make kerf cutting portions of a core, or the cutting members affixed to the kerf cutting portions of a core wider than the body of the core so the body of the core will not bind within the kerf as the cutting progresses. It is further known that cutting efficiency is improved substantially if cutting debris can be rapidly removed from the work material as cutting progresses. Prior art abrasive coated cores or prior art cutting members, however, tend to wear rapidly and in such fashion that the width of the cutting portion of the tool, or the cutting members affixed to the cutting portion of the tool are reduced as the cutting progresses, preventing rapid removal of cutting debris and allowing the core body to interfere with the sides of the kerf. Both conditions lead to reduced cutting efficiency and rapid failure of the cutting tool while expensive diamonds or other abrasive particles remain unused.
Prior art efforts at resolving problems associated with cutting members have included variations in the wear characteristics of the matrix material used to consolidate the cutting members and using a greater number of hard particles embedded in the sides of the cutting member than in the middle so that the sides will wear longer to maintain the desired kerf width. Also, various shapes and profiles of cutting members within their structural limits have been devised in an effort to facilitate rapid removal of cutting debris or improve the wear pattern.
Efforts to further improve cutting characteristics of abrasive cutting tools based upon prior art technology have been limited by lack of an inherent structural integrity of the cutting members thereby preventing the use of efficiency enhanced configurations of the cutting members; the lack of debris clearance immediately surrounding each abrasive particle until the matrix material has been worn away thereby leaving the cutting members vulnerable to abrasive particle loss while substantial cutting value remains; non uniform distribution of hard particles throughout the matrix material or on the surface of the core material thereby causing loss of cutting value by over concentration of hard particles in a small area, or by premature loss of hard particles as their mutual support is eroded. As a result, the above mentioned efforts of the prior art technology to improve the cutting characteristics of abrasive cutting tools have been limited.
SUMMARY OF THE INVENTION
The present invention provides for structurally independent cutting members to be mounted on a core for use as a cutting tool, or for structurally independent cutting tools having a composite cutting portion and a composite non-cutting core portion, or for composite, structurally independent cutting tools, the cutting members or composite cutting tools. By using a cellular or mesh-type material applied in a way described in U.S. Pat. Nos. 4,925,457, 5,049,165, and 5,092,910 for locating, positioning, placing and supporting hard particles within the material's structure, as well as using the mesh-type material as a structural component, design latitude is expanded to provide for enhanced cutting members or cutting portion configurations. Maximum productivity of the cut and/or cutting life are obtained from the hard abrasive particles during cutting action before they are lost. Maximum initial debris clearance adjacent to each hard particle is assured by the spacing and configuration of the cutting members which can provide ample channels for removal of cutting debris, and to supply and remove coolant when it is used. The cutting members or core configurations in accordance with the present invention may comprise a plurality of mesh layers, shapes and locations to achieve the effect of one cutting member having both high pressure and low pressure cutting forces to correspond, respectively, to applied normal and lateral cutting forces. The total power for driving the cutting tool is reduced, and channels for providing coolant and removing coolant and debris are improved. A cutting tool of the present invention can be produced at reduced costs, and the tool is reliable, exhibits good performance, is safe, and is compatible with the requirements of a user.
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“Fundamentals of Designing and Technology of Manufacturing Abrasive and Diamond Tools,” Edited by Yu M. Kevalchuk, Moscow, Mashinostroenie Publishing House, 1984, pp. 172-174, w/English translation of Official Action issued by Russian Patent Office indicating relevance of reference.
Finnegan Henderson Farabow Garrett & Dunner L.L.P.
Rose Robert A.
Ultimate Abrasive Systems, L.L.C.
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