WO2012121943A2

WO2012121943A2 - Dual bladed jig saw

Info

Publication number: WO2012121943A2
Application number: PCT/US2012/027072
Authority: WO
Inventors: Marc Vitantonio; Trevor Jackson; John Nottingham; Donald C. FUCHS; John Spirk; Robert Soreo; Jeffrey Taggart
Original assignee: Infusion Brands, Inc.
Priority date: 2011-03-08
Filing date: 2012-02-29
Publication date: 2012-09-13
Also published as: WO2012121943A3; CN103857498A

Abstract

A jig saw for cutting material. The jig saw includes a drive system and a gear arrangement. The gear arrangement is designed to cause first and second jig saw blades to partially or folly reciprocate in opposite directions relative to one another. The gear arrangement is connected or interconnected to first and second blade carrying arms. The first jig saw blade is connected to the first blade carrying arm and the second jig saw blade is connected to the second blade carrying arm. The gear arrangement is designed to cause the first and second blade carrying arms to move when the drive system is activated to thereby cause the first and second jig saw blades to partially or fully reciprocate in opposite directions relative to one another.

Description

DUAL BLADED JIG SAW

The present invention claims priority on United States Provisional Application Serial Nos. 61/450,196 filed March 8, 201 1 ; 61/547,092 filed October 14, 201 1 ; and 61/560,457 filed November 16, 201 1, all of which are incorporated herein by reference.

The present invention is related cutting devices, particularly directed to jig saws, more > particularly directed to a jig saw that includes a plurality of jig saw blades that can be moved independently of one another, and still more particularly to a jig saw that includes two jig saw blades that can be simultaneously moved in opposite directions to one another during the cutting of material.

BACKGROUND OF THE INVENTION

' Electric powered jigsaws are well known in the art. A conventional jigsaw typically includes an electric motor contained within a housing, and a shoe positioned beneath the housing. The shoe generally includes a bottom surface designed to slide or ride along the top surface of a work piece. An open-ended slot is formed at a front end of the shoe. A straight, bayonet-type saw blade extends downward from the housing through the front slot. A leading edge of the blade generally includes a plurality f teeth that face in a forward direction toward the front of the shoe. In use, the blade is reciprocated in a generally up-and-down direction by the motor that is located in the housing of the jig saw. As the blade reciprocates, the jigsaw is manually advanced in a forward direction such that the teeth of the blade cut into a work piece. As the blade cuts into the work piece, the bottom surface f the shoe rides over the top f the work piece.

Some jigsaws are capable of producing an orbital blade motion. Such a motion has a rectilinear component of a generally up-and-down nature, and fore-and-aft motion advancing the cutting blade into the work piece. Typically, the blade advances on the cutting stroke, which is conventionally in the upstroke on most jig saws.

A variety of different jig saw blades can be utilized with a jigsaw. For example, jig saw blades having different sizes, different teeth configurations, different teeth sizes, and different blade materials can be used. The jig saw can include a blade clamping system that allows the jig saw blades to be quickly and easily interchanged. Jigsaws are commonly used to make curved cuts along relatively short radiuses. Jig saws are commonly used in the automotive industry, wood fabrication industry, upholstery industry, leather industry and the like. The reciprocating jig saw blade can be used to cut straight and curve lines on the wood, metal, plastic, rubber and other types of materials. The jig saw can also be used for bevel cutting by adjusting the angle of the shoe positioned beneath the housing of the jig saw.

Several non-limiting prior art jig saws are illustrated in United States ⁵atent Nos.

8,096,055; 8,082,671; 8,024,865; 8,033,026; 8,024,865; 7,937,841; 7,748,125; 7,596,873;

7,506,447; 7,497,154; 7,497,017; 7,350,302; 7,152,329; 7,131,206; 7,111,405; 6,553,675;

6,357,124; 6,357,123; 6,342,001; 6,282,793; 6,241,027; 6,230,411; 6,178,646; 6,033,746;

5,819,421; 5,727,322; 5,644,845; 5,487,221; 4.870,755; 4,837,935; 4,730,397; 4,719,701;

4,693,009; 4,628,459; 4.603.614; 4,512,078; 4,318,224; 4,240,204; 4,238,884; 4,137,632;

4,043,311; 3,982,521; 3,938,251; 0649,422; 0647,379; 0639,630; 0634.171; 0606,820;

D599,183; D592,925; 0592,924; 0584,589; 0581,761: D581,760; D581.234; 0578,366;

D574,687; 0573,859; 0573,858; D572,555; D567,048; D566,504; D562,096; D560,455;

D559,642; 0539.625; 0538, 16; 0532.664; D531,869; D530,173; D527,968; D527,598;

D525,844; D525.098; D525,097; D524,622; D524,621; D524,620; D523,311; D522,829;

D522,335; D521.834; D 5 ί ^ « «3 *5 ^ 0520,318; D519,806; 0519.805; D519,804; D51 ,346;

D519,014; D518,697; D517,386; D505.851 ; D491,034; 0489,239; 0489,238; 0486,711:

D485J47; D484,381; 0483,637; D476.871; D475,264; 0474,385; D474,384; D468,983;

D465,713; D463,963; D462.591; D455,328; 0454,476; D451,356; D447,037; D446.703;

D440,474; D426,124; D423,314; D420,876; D415,941; D414,094; D413,243; D410,183;

D409,469; 1)404.274: 0339.276: D337,709; D328.751; 0325,588; D297,208; 0295.945;

D287,930; 0282.625: D277.451; and Unites States Publication Nos. 2012/0000080;

2012/0000053; 2011/0131820; 2010/0307012; 2010/0126328; 2010/0107427; 2010/0050443; 2010/0000388; 2010/0000100; 2009/0144992; 2009/0106986; 2009/0077819; 2009/0077816; 2009/0077814; 2009/0025233; 2008/0289198; 2008/0289196; 2008/0222901; 2008/0209742; 2007/0289148; 2007/0214659; 2008/0189962; 2007/0107238; 2007/0050994; 2007/0050993; 2006/0179668; 2006/0090355; 2005/0099801; 2004/0045425; 2004/0040161; 2003/0196337;

- - 2003/0121 161 ; 2002/0174550; 2002/0170185; 2002/013481 1 ; 2002/0073822; all of which are incorporated herein by reference.

When using a standard jig saw. the jig saw blades are constantly exerting an upward and downward force as the jig saw blade moves up and down when cutting a material. The use of a shoe on the jig saw held to counter the downward force. The upward force is generally countered by the used pushing downwardly on the jig saw during the cutting operation. Such upward force created by the jig saw blade must be continuously countered by the user during the cutting process. This constant downward force being exerted by the user can result in fatigue to the user over time. Once the user becomes fatigued, the user must stop use of the jig saw or risk injury to the user, damage to the jig saw and/or damage to the material being cut by the jig saw. Furthermore, during use of the jig saw, the jig saw blade may cause a periodic jerking action when cutting through the material. If the user does not properly counter such periodic jerking action, the user risks injury, damage to the jig saw and/or damage to the material being cut by the jig saw.

During operation of the jig saw, there can be significant vibration caused by the jig saw during the cutting of material. Many prior art jig saws include a motor drive that rotates an eccentric wheel in order to make the jig saw blade reciprocate. During the operation of the jig saw the movement of the jig saw blade can create significant vibration in the axis of movement of the jig saw blade. Some prior art jig saws include the use of counter weights on the eccentric wheel to reduce the amount of vibration. However, such designs have had limited success and can result in other types of vibrations being formed due to the use of the counter weights.

In view of the current state of the art of jig saws, there is a need for a jig saw that reduces the upward/downward force, vibration and jerking actions caused by the jig saw blade during the cutting operation, reduces fatigue to the user when using the jig saw, improves accuracy of the cutting operation through material, and provides for smoother cuts through the material.

SUMMARY OF THE INVENTION

The present invention is directed to jig saws, more particularly directed to a jig saw that includes a plurality of jig saw blades that can be moved independently of one another, and still more particularly to a jig saw that includes two jig saw blades that can be simultaneously moved in opposite directions to one another during the cutting of material. Prior art jig saws generally include a single jig saw blade that reciprocated in an up and down motion. Jig saws have been developed that include two jig saw blades; however, the two jig saw blades are designed to move in paral lel with one another during the cutting of material. The present invention pertains to the novel concept of including two jig saw blades that can reciprocate together in the same direction, but at differing rates of rotation, or be reciprocated in opposite directions from one another during the cutting of material. The present invention contemplates a power tool that is dedicated for use with one or more jig saw blades. The ability to reciprocate two jig saw blades at different rates and/or in opposite directions from one another during the cutting of material can result in 1 ) improved cutting of material by the jig saw blades. 2) reduced the vibration caused by the cutting of material by the jig saw blades and/or operation of the jig saw and thereby reduce fatigue to the user when using the jig saw and or facilitate in the ease, quality and/or accuracy of a cut in a material during the use of the jig saw, 3) improvements in the speed and/or accuracy of the cutting operation through a material, 4) a reduction of the upward/downward forces on the user when using the jig saw to cut through material and thereby reduce fatigue to the user when using the jig saw and/or facilitate in the ease, quality and/or accuracy of a cut in a material during the use of the jig saw, 5) a reduction of the jerking actions caused by the jig saw blades during the cutting operation and thereby reduce fatigue to the user when using the jig saw and/or facilitate in the ease, quality and/or accuracy of a cut in a material during the use of the jig saw, 6) improvements in the accuracy of the cutting operation through material, and/or 7) providing for a smoother cuts and/or less abrupt cut through the material.

In one non-limiting aspect of the present invention, the jig saw blades are caused to reciprocate in opposite directions to one another during the cutting of a material. The speed or rate of reciprocation of the two jig saw blades when reciprocating in opposite directions can be the same or different. In one non-limiting aspect of the invention, the speed or rate of reciprocation of the two jig saw blades, when reciprocating in opposite directions, can be the same.

In another and/or alternative non-limiting aspect of the present invention, the two jig saw blades can have the same or different length, tooth location and or shape. In one non-limiting embodiment of the invention, the length of the two jig saw blades is the same; however, this is not required. In another and/or alternative non-limiting embodiment of the invention, the tooth location of the two jig saw blades is the same; however, this is not required. Generally, the tooth location is on the front edge of the jig saw blade; however, it can be appreciated that teeth can be

> positioned on both the front and back edge of the jig saw blade; however, this is not required. In still another and or alternative non-limiting embodiment of the invention, the shape of the two jig saw blades is the same; however, this is not required. When the length, tooth location and shape of the two jig saw blades are the same, the two jig saw blades can be interchangeable with one another without affecting the operation of the jig saw; however, this is not required. In yet

I another and/or alternative non-limiting embodiment of the invention, the connection arrangement of the two saw blades can be the same or different. When the jig saw blades have the same connection arrangement, either jig saw blade can be connected to the first or second blade carrying arm without affecting the operation of the jig saw; however, this is not required. When the jig saw blades have a different connection arrangement, one jig saw blade can be designed to connect only to one of the blade carrying arms and the other jig saw blade can be designed to connect only to the other blade carrying arm; however, this is not required.

In still another and/or alternative non-limiting aspect of the present invention, the jig saw can optionally include a quick, connect/release arrangement for one or both jig saw blades; howev er, this is not required. The configuration of the quick connect/release arrangement, when included on the jig saw, is non-limiting. In one non-limiting configuration, this is provided one or more depressible buttons on the jig saw to enable one or both jig saw blades to be connected to and/or released from the blade carrying arms on the jig saw. The location of the one or more buttons on the jig saw is non-limiting. As can be appreciated, one or more of the jig saw blades can be connected to the blade carrying arms on the jig saw by use of a screw, a hex bolt, etc. instead of a blade carrying amis on the jig saw.

In yet another and/or alternative non-limiting aspect of the present invention, the configuration of the cutting teeth on the first and second jig saw blades can be the same or different. In one non-limiting embodiment of the invention, the teeth configuration on each of the jig saw blades is the same. In another non-limiting embodiment of the invention, the teeth configuration on each of the jig saw blades is different. In still another non-limiting embodiment of the invention, the teeth configuration on one or both of the jig saw blades enables the jig saw blades to cut material when moving in both an upward direction and downward direction; however, this is not required. In yet another non-limiting embodiment of the invention, the one or more teeth on one or both of the jig saw blades angle outwardly from the central cutting axis of the jig saw. Such a jig saw blade configuration can be used to 1) cause one or both jig saw blades to move toward one another during the cutting of material, 2) facilitate in the movement of cut material away from one or both jig saw blades, and/or 3) increase the ease of cutting through a material; however, this is not required. The configuration of the teeth of either of the two jig saw blades is non-limiting.

In still yet another and/or alternative non-limiting aspect of the present invention, the jig saw is a dedicated tool for use with one or more jig saw blades. The jig saw can be battery powered and/or powered by a power cord. In one non-limiting embodiment, when two jig saw blades are connected to the jig saw, the jig saw includes gearing that enables the two jig saw blades to reciprocate in opposite directions; howev er, this is not required. The jig saw can include gearing that enables the two jig saw blades to be reciprocated in opposite directions at the same or different speeds. In another and/or alternative non-limiting embodiment of the invention, the jig saw can include one or more optional features such as, but not limited to, a "continuous on" button, a button to activate a light or laser, a level indicator, a speed controller, a "lock off button, battery powered motor, rechargeable battery, removable battery, vibration reducing hand grip, reduced slip hand grip, tiltable handle, rotatable handle, etc.; however, this is not required.

In another and/or alternative non-limiting aspect of the present invention, the jig saw can optionally include laser or light switch to activate and/or deactivate one or more lights or lasers on the jig saw. The location of the switch and one or more lasers and/or lights on the jig saw is non-limiting. When one or more lasers and/or lights are included on the jig saw, at least one laser and/or light is generally located at the front or front portion of the jig saw to 1) illuminate a region about the jig saw blades to facilitate in the illumination of the region to be cut by the jig saw blades, and/or 2) create a guide line or cut line to facilitate in guiding the one or more jig saw blades along the material to be cut; however, this is not required. In one non-limiting arrangement, the laser or light switch is located on a region of the jig saw that is grasped by the user (e.g., handle, etc.) when using the jig saw; however, this is not required. The laser or light switch can be desi ned to be a depressible or contact switch that automatically causes one or more laser and/or lights to illuminate when the jig saw is grasped by the user during use of the jig saw; however, this is not required. In such an arrangement, the switch can be located on top of or hidden beneath an outer surface of the jig saw.

In still another and/or alternative non-limiting aspect of the present invention, the jig saw can optionally include a shoe used to facilitate in the use of the jig saw. The configuration of the shoe is non-limiting. In one non-limiting embodiment of the invention, the shoe, when used, can be designed to be detachable from the body of the jig saw; however, this is not required. In another and/or alternative non-limiting embodiment of the invention, the shoe, when used, can include a vacuum attachment that can be connected to a vacuum source to drawn cut material away from the one or more jig saw blades during use; however, this is not required. The vacuum connection, when used, can be located at the rear portion of the shoe; however, this is not required. In still another and/or alternative non-limiting embodiment of the invention, the shoe, when used, can be tiltable to allow for angled cutting of the material by the one or more jig saw blades; however, this is not required.

In yet another and/or alternative non-limiting aspect of the present invention, the jig saw can optionally include one or more blade guides for use with one or both jig saw blades. The one or more blade guides can include a roller guide; however, this is not required. The one or more blade guides, when used, can be designed to 1 ) facilitate in maintaining the alignment of the one or both jig saw blades during the operation of the jig saw and/or the cutting of material, 2) facilitate in maintaining the relative position and/or spacing of the two jig saw blades from one another during the operation of the jig saw and/or the cutting of material, and/or 3) provide rear support to one or both jig saw blades to resist rear movement of one or both jig saw blades during the cutting of material. The configuration of the one or more blade guides and the location of the one or more blade guides are non-limiting. In one non-limiting embedment, the one or more blade guides, when used, are located at or closely adjacent to the shoe of the jig saw; however, this is not required. In another and/or alternative non-limiting embodiment, the one or more blade guide can include one or more rollers having one or more blade slots. Each jig saw blade can be designed to fit into a single blade slot or both jig saw blades can be designed to fit into a single blade slot. The one or more rollers, when used, can be designed to rotate as the one ϊ or more jig saw blades move in the one or more blade slots; however, this is not required. As can be appreciated, the one or more blade guides can include one or more blade slots that are formed on structures other than one or more rollers; however, this is not required. The blade slot can be a structure having a fixed position or can be a movable structure that is biased (e.g., spring biased) in a certain position.

I In still yet another and or alternative non-limiting aspect of the present invention, the two jig saw blades can optionally include a connector arrangement that connects the two jig saw blades together and enables the two jig saw blades to reciprocate in opposite directions. The configuration of the connection arrangement is non-limiting. In one non-limiting arrangement, the connection arrangement includes a pin and slot arrangement wherein one of the jig saw blades includes a slot and the other jig saw blade includes a pin that is designed to be moveable in the slot of the other jig saw blade. The connection arrangement, when used, can be designed to facilitate in maintaining the spacing of the two jig saw blades from each other during the operation of the jig saw and/or the cutting of material by the two jig saw blades.

In another and/or alternative non-limiting aspect of the present invention, the jig saw optionally includes a gearing arrangement that enables the user to select a plurality of stroke options for the one or more jig saw blades. As defined herein, "stroke" is the difference been the maximum upward and downward position of the jig saw blade during the operation of the jig saw. The gearing arrangement can be designed to enable two or more different stroke values to be used when cutting of the material. In one non-limiting arrangement, the one or more jig saw blades can have a different stroke value by merely selecting the rotation direction of the motor of the jig saw. For example, when the motor is selected to operate in the clockwise direction, the stroke value of the one or more jig saw blades can be a stoke value A (e.g., 0.75 inches, 1 inch, etc.), and when the motor is selected to operate in the counterclockwise direction, the stroke value of the one or more jig saw blades can be a stoke value B (e.g., 0.5 inches, 0.25 inches, etc.). As can be appreciated, the gear arrangement can be designed to change the stroke valve without having to change the direction of the motor.

In still another and/or alternative non-limiting aspect of the present invention, the jig saw optionally includes a gearing arrangement that includes an eccentric cam arrangement to enable two jig saw blades to reciprocate in opposite directions during the operation of the jig saw. As can be appreciated, the gearing arrangement can include other arrangements that are absent an eccentric cam arrangement to enable two jig saw blades to reciprocate in opposite directions during the operation of the jig saw.

It is one non-limiting object of the present invention to provide a multi-blade jig saw.

It is another and/or alternative non-limiting object of the present invention to provide a multi-blade jig sa wherein two or more jig saw blades reciprocate in the opposite direction from one another and/or reciprocate at the same or different rates of reciprocation from one another.

It is still another and/or alternative non-limiting object of the present invention to provide a jig saw that is dedicated to the use with one or more jig saw blades.

It is yet another and/or alternative non-limiting object of the present invention to provide a jig saw that improves the cutting of material by the jig saw blades.

It is still yet another and/or alternative non-limiting object of the present invention to provide a jig saw that reduces the vibration caused by the cutting of material by the jig saw blades and/or operation of the jig saw and thereby reduce fatigue to the user when using the jig saw and/or facilitate in the ease, quality and/or accuracy of a cut in a material during the use of the jig saw.

It is another and/or alternative non-limiting object of the present invention to provide a jig saw that improves in the speed and/or accuracy of the cutting operation through a material.

It is still another and/or alternative non-limiting object of the present invention to provide a jig saw that reduces the upward/downward forces on the user when using the jig saw to cut througli material and thereby reduce fatigue to the user when using the jig saw and/or facilitate in the ease, quality and/or accuracy of a cut in a material during the use of the jig saw. It is yet another and/or alternative non-limiting object of the present invention to provide a jig saw that reduces of the jerking actions caused by the jig saw blades during the cutting operation and thereby reduce fatigue to the user when using the jig saw and/or facilitate in the ease, quality and/or accuracy of a cut in a material during the use of the jig saw.

> It is still yet another and/or alternative non-limiting object of the present invention to provide a jig saw that improves in the accuracy of the cutting operation through material.

It is another and/or alternative non-limiting object of the present invention to provide a jig saw that provides for a smoother cuts and/or less abrupt cut through the material.

It is still another and/or alternative non-limiting object f the present invention to provide ) a jig saw wherein the speed or rate of reciprocation of the two jig saw blades when reciprocating in opposite directions can be the same or different.

It is yet another and/or alternative non-limiting object of the present invention to provide a jig saw wherein the two jig saw blades can have the same or different length, tooth location and/or shape.

It is still yet another and/or alternative non-limiting object of the present invention to provide a jig saw wherein the connection arrangement of the two jig saw blades can be the same or different.

It is another and/or alternative non-limiting object of the present invention to provide a jig saw that includes a quick connect/release arrangement for one or both jig saw blades.

It is still another and/or alternative non-limiting object of the present invention to provide a jig saw that the configuration of the cutting teeth on the first and second jig saw blades can be the same or different.

It is yet another and/or alternative non-limiting object of the present invention to provide a jig saw that one or more teeth on one or both of the jig saw blades angle outwardly from the central cutting axis of the jig saw so as to cause one or both jig saw blades to move toward one another during the cutting of material, to facilitate in the movement.

It is still yet another and/or alternative non-limiting object of the present invention to provide a jig saw that includes gearing that enables the two jig saw blades to be reciprocated in opposite directions at the same or different speeds. It is another and/or alternative non-limiting object of the present invention to provide a jig saw that includes a laser or light switch to activate and/or deactivate one or more lights or lasers on the jig saw.

It is still another and/or alternative non-limiting object of the present invention to provide a jig saw that includes a shoe having a vacuum attachment that can be connected to a vacuum source to draw cut material away from the one or more jig saw blades during use. As can be appreciated, the vacuum attachment can also or alternatively be used as a blower source to blow cut material away from the one or more jig saw blades during use.

It is yet another and/or alternative non-limiting object of the present invention to provide a jig saw that includes a shoe that can be tiltable to allow for angled cutting of the material by the one or more jig saw blades.

It is still yet another and/or alternative non-limiting object of the present invention to provide a jig saw that includes a blade guide for use with one or both jig saw blades to facilitate in maintaining the alignment of the one or both jig saw blades during the operation of the jig saw and/or the cutting of material, to facilitate in maintaining the relative position and/or spacing of the two jig saw blades from one another during the operation of the jig saw and/or the cutting of material, and/or to provide rear support to one or both jig saw blades to resist rear movement of one or both jig saw blades during the cutting of material.

It is another and/or alternative non-limiting object of the present invention to provide a jig saw that includes a connector arrangement that connects the two jig saw blades together and enables the two jig saw blades to reciprocate in opposite directions.

It is still another and/or alternative non-limiting object of the present invention to provide a jig saw that includes a gearing arrangement that enables the user to select a plurality of stroke options for the one or more jig saw blades.

It is yet another and/or alternative non-limiting object of the present invention to provide a jig saw that includes a gearing arrangement that includes an eccentric cam arrangement to enable two jig saw blades to reciprocate in opposite directions during the operation of the jig saw. These and other objects and advantages will become apparent to those skilled in the art upon reading and following the description taken together with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Reference may now be made to the drawings which illustrate various preferred embodiments that the invention may take in physieal form and in certain parts and arrangement of parts wherein:

FIGURE 1 is a side elevation view of one non-limiting jig saw that includes two jig saw blades in accordance with the present invention;

FIGURE 2 is an opposite side elevation view of the jig saw of FIGURE 1 ;

FIGURE 3 is a side view of the jig saw of FIGURE 1 ;

FIGURE 4 is an opposite side view of the jig saw of FIGURE 1 ;

FIGURE 5 is a cross-sectional view of the jig saw of FIGURE 1 ;

FIGURE 6 is an exploded view of the jig saw of FIGURE 1 ;

FIGURE 7 is a front elevation view of one non-limiting the gear arrangement of the jig saw of FIGURE 1 ;

FIGURE 8 is a side view of the gear arrangement of FIGURE 7; and,

FIGURE 9 is a side elevation view of another non-limiting jig saw that includes two jig saw blades in accordance with the present invention, a modified housing configuration and a blade quick release button.

DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS

Referring now to the drawings wherein the showings are for the purpose of illustrating one non-limiting embodiment of the invention only and not for the purpose of limiting same, FIGURES 1 -8 illustrate non-limiting embodiments of the jig saw in accordance with the present invention.

Referring now to FIGURES 1 -4, therein is illustrated one non-limiting fully assembled ig saw 100 in accordance with the present invention. As can be appreciated, the overall shape and size of the jig saw is non-limiting. As can also be appreciated, the color of the jig saw and the materials used to make the jig saw are non-limiting. As illustrated in FIGURES 1 -4, the jig is designed to be a handheld power tool; however, it can be appreciated that the jig saw can be designed to be secured to a robotic arm or fixed to some type of machine.

The jig saw includes a housing 1 10 that includes a first and second main body shell 120, 130, and a front face plate 140. A decorative cover 144 can optionally be used and connected to

5 the front surface of the front face plate. The shape of these three components of the housing is non-limiting. As can also be appreciated, the housing can include less than three components or more than three components. The housing is designed to partially or fully enclose the drive system and gear arrangement of the jig saw which will be described in more detail below. One or more buttons or switches 150, 160 can he used to enable the user to activate/deactivate the

) drive system of the jig saw and/or activate/deactivate one or more lasers or lights 170 on the jig saw. The location of the one or more buttons or switches on the housing is non-limiting. As illustrated in FIGURE 1 , switch 150 is located on the side of body shell 130. The switch is used to activate/deactivate the drive system of the jig saw. Switch 150 could also or alternatively be used to activate/deactivate one or more lasers or lights on the jig saw; however, this is not

! required. Switch 150 could also be designed to select the speed or the drive system; and/or cause the drive system to rotate an armature in the clockwise or counterclockwise direction; however, this is not required. Button 160 is designed to be positioned under the outer surface of the housing; however, this is not required. Button 160 is also designed to be activated when the user grasps the body of the housing during use of the jig saw, which in turn activates laser or light 170. As can be appreciated, button 160 can be designed to require manual activation/deactivation instead of automatic activation/deactivation; however, this is not required. The inclusion of button 160 and laser or light 170 on the jig saw is optional. The laser or light 170, when used, can facilitate in a) illuminating a region about the jig saw blades to facilitate in the illumination of the region to be cut by the jig saw blades, and/or b) creating a guide line or cut line to facilitate in guiding the one or more jig saw blades along the material to be cut; however, this is not required. The laser or light 170, when used, is generally positioned on the front region of the housing; however, this is not required. As illustrated in FIGURES 5 and 6, laser or light 170 is positioned in a light cavity 142 that is positioned on front face plate 140. Although not shown, a handle can be connected to the top portion of housing 1 10; however, this is not required. The handle, when used, can be designed to be used by a user to grasp and direct the jig saw during operation of the jig saw. The handle can optionally include vibration dampening features to reduce the amount and/or degree of vibrations transmitted from the jig saw to the user during the operation of the jig saw. The handle, when used, can optionally include buttons or switches 150, 160.

A cord strain attachment 180 can be optionally positioned on the rear portion of the housing. When the drive system of the jig saw is powered by an electric current from a wall outlet, electric generator, etc.. the jig saw includes an electric cord 190 having a plug, not shown. The cord strain attachment is used to inhibit or prevent damage to the electric cord at the point of entry of the electric cord into the housing. When the jig saw is battery powered, the housing generally includes a battery cavity and/or connection, not shown, and the cord strain attachment 180 and electric cord 190 are eliminated.

Referring to FIGURES 1 -6 and 9, the jig saw can optionally include a shoe 200. The shoe can be permanently connected or detachably connected to housing 1 10. The shoe is designed to enable the jig saw to glide and be moved on the top surface of a material to be cut by the jig saw. The shape, size and configuration of the shoe are non-limiting. The shoe can be designed to be tiltable to enable the jig saw to form angled cuts in a material; however, this is not required. The shoe generally has a front opening or slot 202 that enables the one or two jig saws blades to pass through. The shape of the opening or slot is non-limiting. The opening or slot can be shaped and/or markers can be positioned about the opening or slot to function as a guide or positioning feature to enable the user to cut a material in a desired location; however, this is not required. When a light and/or laser is used on the jig saw, the light and/or laser can be directed to shine light into and/or about opening or slot 202; however, this is not required. The shoe can optionally include a vacuum port 204 that is designed to be connected to a vacuum source, not shown. The first and/or second main body shells 120, 130 can optionally include vacuum shells 122, 132 that form a vacuum cavity 210 when the two main body shells are connected together. As illustrated in FIGURES 1-5 and 9, the vacuum cavity connects to the vacuum port 204 on shoe 200. The vacuum port and vacuum cavity, when used, facilitate in the removal of cut material that remains about the one or two jig saw blades. Such material removal 1) facilitates in enable the use to proper guide the one or more jig saw blades on the material being cut and or 2) results in a cleaner and better cut when cutting material. As can be appreciated, the removal of cut material by a vacuum source and/or by a blower can have other or additional advantages.

Referring now to FIGURES 5-8, the jig saw includes a novel gear arrangement 300 that can be used to reciprocate a first jig saw blade 500 or a first and second jig saw blade 500, 600. When two jig saw blades are connected to the gear arrangement, the gear arrangement is designed to cause the two jig saw blades to reciprocate in opposite directions. Many different gear arrangements can be used to cause the two jig saw blades to reciprocate in opposite directions. One non-limiting gear arrangement is illustrated in FIGURES 5-8. A drive system such as a motor 250 is used to cause an armature 260 to rotate a motor cooling fan blade 270. The cooling fan blade is an optional component that can be connected to the armature to cool the motor during operation. The front portion of the armature includes an axle portion 262. Generally, the cooling fan blade is positioned on axle portion 262. The motor is designed to cause the armature to rotate in a clockwise and/or counterclockwise direction. The motor can be a variable speed motor; however, this is not required.

The gear arrangement 300 includes a main gear housing 310, a first and second side housings 320, 330. As can be appreciated, the gear arrangement can include less than three or more than three housing components. The shape and size of the housing components are non- limiting. A portion of the axle portion 262 extends through an opening in main gear housing 310. A bearing 340 can also be positioned on the axle portion 262 within the main gear housing 310 to maintain the position of the armature 260 relative to the gear arrangement 300. The end of the axle portion 262 generally includes a gear region that is designed to mesh with the teeth on eccentric gear 350 and cause the eccentric gear to rotate when the armature 260 is caused to rotate by motor 250. As can be appreciated, other or additional arrangements can be used to cause eccentric gear 350 to rotate when the armature 260 is caused to rotate by motor 250. Eccentric gear 350 is mounted on shaft 360 to main gear housing 310. Shaft 360 is designed to pass through a central opening 352 in eccentric gear 350 and connect to main gear housing 310. Eccentric gear 350 is mounted so that the bottom portion of eccentric gear 350 contacts the gear end of the axle portion 262. As can be appreciated, the end of the axle portion 262 could be directly connected to eccentric gear 350 to cause eccentric gear 350 to rotate when armature 260 is caused to rotate by motor 250.

Gear arrangement 300 includes a connecting arm carrier housing system that includes a front arm carrier 370, two side arm carriers 380, 390, and back arm carrier 400. The connecting arm carrier housing system is designed to hold together and guide the movement of the two connecting arms 410, 420. The two connecting arms include a top opening 41 . 422 that is designed to be connected to eccentric cam 430. Eccentric cam 430 includes first and second mount surfaces 432, 434. The face of the first mount surface 432 includes one or more openings 436 that receive a pin or screw, not shown, to connect to the one or more openings 354 in eccentric gear 350. As can be appreciated, other or additional connection arrangements can be used. When the eccentric cam 4 0 is connected to the eccentric gear 350. a portion of the eccentric cam 430 generally overlies all or a portion of the head of shaft 360; however, this is not required. Top opening 412 of connecting arm 410 is designed to connect to first mount surface 432 of eccentric cam 430, and top opening 422 of connecting arm 420 is designed to connect to second mount surface 434 of eccentric cam 430. The slots 382, 392 in side arm carriers 380, 390 are designed to receive the sides of connecting arms 410, 420 and maintain a spacing between the connecting arms. An arm plate 431 is also positioned between the connecting arms to maintain a spacing between the connecting arms. The top of arm plate 431 includes a recessed portion so that when eccentric cam 430 moves as the eccentric gear 350 rotates, the eccentric cam does not contact arm plate 431. A second arm plate 440 is positioned between connecting arm 420 and back arm carrier 400. The front face plate 140, and first and second side housings 320, 330 are designed to connect to main gear housing 310 to thereby secure the connecting arm carrier housing system in the main gear housing 310. The manner in which the components are connected together is non-limiting (e.g., screw, pin, adhesive, melt bond, snap-lock arrangement, nut and bolt, etc.).

During operation, when eccentric gear 350 is caused to rotate by motor 250, the eccentric cam 430 that is connected to the eccentric gear 350 moves in a circular path with the eccentric cam 430. When the eccentric gear 350 is positioned such that openings 354 are positioned above shaft 360, the first mount surface 432 of eccentric cam 430 is in the upper position and the second mount surface 434 of eccentric cam 430 is in the lower position. When the eccentric gear 350 is positioned such that openings 354 are positioned below shaft 360, the first mount surface 432 of eccentric cam 430 is in the lower position and the second mount surface 434 of eccentric cam 430 is in the upper position. As such, as eccentric gear 350 and the mount surfaces move between the upper and lower position, the two connecting arms 41 . 420 are cause to reciprocate in opposite directions from one another. Generally, the armature that is rotated by the motor has an axis that is non-parallel to the movement of the two jig saw blades or longitudinal axis of the jig saw blades. In one non-limiting configuration the angle between the axis of the armature and the axis of movement of the two jig saw blades or longitudinal axis of the jig saw blades is about 1 5- 165, typically about 30- 1 50, more typically about 45- 1 5', still more typically about 60^"- 12(1. and even more typically about 90'.

As can be appreciated, the gear arrangement illustrated in FIGURES 5-8 is just one non- limiting gear arrangement that can be used to cause the first and second jig saw blades to periodically or always reciprocate in opposite directions. In one alternative gear arrangement, the eccentric cam can be designed such that the eccentric cam caused to be rotated by an axle without use of an eccentric gear. The axle can be part of the armature of the motor or be caused to rotate when the armature of the motor rotates. Two connecting arms can be connected to each side of the eccentric cam. The two connecting arms can be connected to the blade carrying arms. When the eccentric cam rotates, the first and second jig saw blades are caused to move up and down. By selecting a certain configuration of the eccentric cam, the rotation of the eccentric cam can be used to cause the first and second jig saw blades to periodically or always reciprocate in opposite directions.

In another alternative gear arrangement, two eccentric gears are use. In such an arrangement of the armature of the motor can directly or indirectly cause the two eccentric gears to rotate. A connecting arm can be connected to each of the eccentric gears, which in turn is connected to the blade carrying arms. The connecting arms are both connected off center of the concentric gears. As such, when the two concentric gears rotate, the first and second jig saw blades are caused to move up and down. By simply adjusting the rotational position of the two concentric gears relative to one another, the rotation of the two concentric gears can be used to cause the first and second jig saw blades to periodically or always reciprocate in opposite directions. As can be appreciated, still other gear arrangements can be used to cause the first and second jig saw blades to periodically or always reciprocate in opposite directions.

ί The bottom of the two connecting arms 410, 420 includes openings 414, 424 that are used to connect the two connecting amis to two blade carrier arms 450, 460. The two blade carrier arms 450, 460 include top openings 452, 462. A pin, screw or other component can be used to connect the two blade carrier arms to the two connecting arms via openings 414, 424 and top openings 452, 462. As the two connecting arms reciprocate when the motor 250 is activate,

> the two connecting arms cause the two blade carrier arms 450, 460 to also reciprocate in opposite directions. The bottom of the two blade carrier arms 450, 460 include blade connectors 454, 464. The blade connectors are designed to connect to jig saw blades 500, 600. As illustrated in FIGURES 1 -5, blade carrier arm 450 is designed to be connected to jig saw blade 500 and blade carrier arm 460 is designed to be connected to jig saw blade 600. The manner in which the blade connectors are designed to connect the jig saw blades is non-limiting. Each blade connector can include a blade slot 456 that is designed to receive a top portion 502, 602 of the jig saw blades. Pins, screws, springs, etc. can be used to secure the jig saw blades to the blade connectors. As illustrated in FIGURE 7, the blade connector can include openings 458, 468 that can be designed to receive a screw, not shown that can be used to secure each jig saw blade in a blade slot of respective blade connectors. As can be appreciated, other or additional arrangements can be used to secure each jig saw blade to a respective blade connector. As illustrated in FIGURE 9, a quick disconnect button 470 is positioned over a portion of the blade carrier arms and is used to quick connect and/or quick disconnect one or both jig saw blades from the blade carrier arms when the quick disconnect button is pressed by a user. The mechanism to enable the quick connect and/or quick disconnect one or both jig saw blades from the blade carrier arms when the quick disconnect button is pressed is non-limiting.

The front edge of each of the jig saw blades includes a plurality of teeth 504, 604. The tooth configuration of the two jig saw blades can be the same or different. Generally, the length, shape and tooth configuration of the jig saw blades are the same to that the jig saw blades can be connected to either blade carrier arm; however, this is not required.

The jig saw can optionally include a blade support arrangement. The blade support arrangement can include a roller guide arm 480. The roller guide arm can include connection openings 482 that are designed to receive a screw, rivet, pin, etc., to enable the roller guide to be connected to housings 320 or 330 and/or to some other portion of the body of the jig saw. The roller guide arm supports one or more rollers 483, 484. A pin 486 and washer 488 can be used to secure the roller to the roller guide arm via openings 488 and enable the rollers to rotate on the pin. The rollers can include a blade groove that receives a back edge 506, 606 of the jig saw blades. The blade support arrangement, when used, maintains the spacing of the two jigsaw blades from one another during the cutting of material and/or resists backward movement of the jig saw blades during the cutting of material. As can be appreciated, the jig saw can be used with one or two jig saw blades.

As illustrated in FIGURES 1 -5 and 7-9, the jig saw blades are positioned closely adjacent to one another. Such positioning of the jig saw blades to one another results in a single cut slot in a material as the jig saw cuts though the material. Generally, the spacing between the jig saw- blades is less than 0.25 inches, typically about 0.001 -0.2 inches, more typically about 0.001-0.1 inches, and still more typically about 0.001 -0.0625 inches. When the spacing between the two jig saw blades is too large, two distinct cuts can be formed by the two jig saw blades. The spacing between the jig saw blades is generally maintained to prevent the formation of two distinct cuts in a material.

Non-limiting features of the jig saw of the present invention are:

• The jig saw can be designed for use with one or two jig saw blades.

The saw blades may feature teeth that will allow the cutting action to be performed on both the forward and return (up and down) stroke.

Custom blade designs may be created for use on or with a variety of materials. By using two jig saw blades can oppose the cutting force with each other, and balance the cutting action of the jig saw. • The jig saw can be designed to improve accuracy, provide smoother cuts on work surfaces, and reduce fatigue on the user.

• Various styles of jig saw blades can be designed for specific cutting purposes,

• The jig saw and mechanisms therein can be made from a variety of materials including, but not limited to, metal, plastic, aluminum or recyclable material.

The jig saw blades can include teeth that will allow the cutting action to be performed on both the upward and downward stroke.

The jig saw can be designed to cause one or both jig saw blades to move in an opposed upward and downward motion, and/or move in an orbiting or elliptical motion.

The jig saw can be designed to enable a user to attach or remove the jig saw blades from the blade holders.

The jig saw can be designed to enable the forwarding and reversing the motor to thereby change the stroke length of the jig saw blades.

The jig saw can be designed to include a rotating handle.

^• The jig saw can be designed to include a pivoting handle.

The jig saw can be designed to be a handheld tool.

• The jig saw can be designed to include one or more electric motors.

The jig saw can be designed to include one or more jig saw blades that include a generally repeating V-shape teeth, W-shape teeth, alternating V-shape and W-shaped teeth, etc.

The jig saw can be designed to include one or more jig saw blades that have blade teeth on one or both sides of one or both jig saw blades.

The jig saw can be designed to include one or more jig saw blades that have blade teeth and wherein every other tooth is angled outwardly.

The jig saw can be designed to include one or more jig saw blades that have blade teeth and wherein one or more teeth are both angled and tapered.

The jig saw can be designed to include one or more jig saw blades that include one or more blade separators to maintain the spacing of the jig saw blades from one another during the operation of the jig saw blades. It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the constructions set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The invention has been described with reference to preferred and alternate embodiments. Modifications and alterations will become apparent to those skilled in the art upon reading and understanding the detailed discussion of the invention provided herein. This invention is intended to include all such modifications and alterations insofar as they come within the scope of the present invention. It is also to be understood that the following claims are intended to cover all of the generic and speci fic features of the invention herein described and all statements of the scope of the invention, which, as a matter of language, might be said to fall therebetween. The invention has been described with reference to the preferred embodiments. These and other modifications of the preferred embodiments as well as other embodiments of the invention will be obvious from the disclosure herein, whereby the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims.

Claims

We claim:

1 . A jig saw for cutting material, said jig saw comprising a drive system and a gear arrangement that is designed to cause first and second jig saw blades to partially or fully reciprocate in opposite directions, said gear arrangement connected or interconnected to first and second blade carrying arms, said first jig saw blade connected to said first blade carrying arm, said second jig saw blade connected to said second blade carrying arm, said gear arrangement causing said first and second blade carrying arms to move when said drive system is activated to thereby cause said first and second jig saw blades to partially or fully reciprocate in opposite directions relative to one another.

2. The jig saw as defined in claim 1 , wherein said drive system includes a single drive axle that can be rotated clockwise and counterclockwise, said single drive axle engagable with said gear arrangement, said rotation of said single drive axle causing said first and second jig saw blades to partially or fully reciprocate in opposite directions relative to one another.

3. The jig saw as defined in claim 1, wherein said gear arrangement including at least one eccentric gear, at least one eccentric cam, or combinations thereof to cause said first and second jig saw blades to partially or fully reciprocate in opposite directions relative to one another.

4. The jig saw as defined in claim 2, wherein said gear arrangement including at least one eccentric gear, at least one eccentric cam, or combinations thereof to cause said first and second jig saw blades to partially or fully reciprocate in opposite directions relative to one another.

5. The jig saw as defined in claim 2, wherein said single drive axle is positioned non-parallel to an axis of movement of a reciprocating axis of said first and second jig saw blades.

6. The jig saw as defined in claim 3 or 4, wherein said single drive axle is positioned non-parallel to an axis of movement of a reciprocating axis of said first and second jig saw blades.

7. The jig saw as defined in claim 3, wherein said gear arrangement includes an eccentric gear, an eccentric cam and first and second connecting arms, said eccentric cam including first and second mount surfaces, said first connecting arm connected to said first mount face of said eccentric cam, said second connecting arm connected to said second mount face of said eccentric cam, said eccentric cam caused to rotate when said eccentric gear is rotated, said eccentric cam causing said connecting arms to move as said eccentric cam is rotated, said first connecting arm connected to interconnected to a first blade carrying arm, said second connecting arm connected to interconnected to a second blade carrying arm, said movement of said connecting arms causing said first and second blade carrying arms to partially or fully reciprocate in opposite directions relative to one another.

8. The jig saw as defined in claims 4-6, wherein said gear arrangement includes an eccentric gear, an eccentric cam and first and second connecting arms, said eccentric cam including first and second mount surfaces, said first connecting arm connected to said first mount face of said eccentric cam, said second connecting arm connected to said second mount face of said eccentric cam, said eccentric cam caused to rotate when said eccentric gear is rotated, said eccentric cam causing said connecting arms to move as said eccentric cam is rotated, said first connecting arm connected to interconnected to a first blade carrying arm, said second connecting arm connected to interconnected to a second blade carrying arm, said movement of said connecting arms causing said first and second blade carrying arms to partially or fully reciprocate in opposite directions relative to one another.

9. The jig saw as defined in claim 7, wherein said eccentric cam is connected to said eccentric gear.

10. The jig saw as defined in claim 8, wherein said eccentric cam is connected to said eccentric gear.

1 1. The jig saw as defined in claim 1 , wherein said first and second jig saw blades are positioned closely adjacent to one another so as to form a single cut in a material as said first and second jig saw blades to partially fully reciprocate in opposite directions relative to one another during the cutting of the material.

12. The jig saw as defined in claims 2- 10, wherein said first and second jig saw blades are positioned closely adjacent to one another so as to form a single cut in a material as said first and second jig saw blades to partially fully reciprocate in opposite directions relative to one another during the cutting of the material.

13. The jig saw as defined in claim 1 , including a shoe that is connected to a body of said jig saw, said shoe including a vacuum attachment that is designed to be connected to a vacuum source so that cut material by said first and second jig saws can be drawn away from the two jig saw blades by the vacuum source.

14. The jig saw as defined in claims 2-12, including a shoe that is connected to a body of said jig saw, said shoe including a vacuum attachment that is designed to be connected to a vacuum source so that cut material by said first and second jig saws can be drawn away from the two jig saw blades by the vacuum source.

15. The jig saw as defined in claim 1 , including a light switch positioned on a body of said jig saw, said light switch designed to activate, deactivate, or combinations thereof a light, a laser, or combinations thereof that is positioned on said body of said jig saw.

16. The jig saw as defined in claims 2- 14. including a light switch positioned on a body of said jig saw, said light switch designed to activate, deactivate, or combinations thereof a light, a laser, or combinations thereof that is positioned on said body of said jig saw.

17. The jig saw as defined in claim 15, wherein said light switch is positioned under and outer surface of said body and is designed to activate said light, said laser, or combinations thereof when a user grasps said body of said jig saw when cutting material with said jig saw.

18. The jig saw as defined in claim 16, wherein said light switch is positioned under and outer surface of said body and is designed to activate said light, said laser, or combinations thereof when a user grasps said body of said jig saw when cutting material with said jig saw.

19. The jig saw as defined in claim 1 , including a blade quick disconnect that is designed to detach, to connect or combinations thereof said first jig saw blade, said second jig saw blade, or combinations thereof from blade carrying arms on said jig saw.

20. The jig saw as defined in claims 2- 18, including a blade quick disconnect that is designed to detach, to connect or combinations thereof said first jig saw blade, said second jig saw blade, or combinations thereof from blade carrying arms on said jig saw.

21. The jig saw as defined in claim 1 , wherein a plurality of teeth on said first jig saw blade, said second jig saw blade, or combinations thereof angle outwardly from a central cutting axis of said two jig saw blades.

22. The jig saw as defined in claims 2-20, wherein a plurality of teeth on said first jig saw blade, said second jig saw blade, or combinations thereof angle outwardly from a central cutting axis of said two jig saw blades.

Fig. 3

Fig. 4

Fig. 5

Fig. 6

Fig. 7 Fig. 8

Fig. 9